2003 F150 Fuel Pump Replacement

[Alan W.]

Just remembered that the 04 year of 150 had a fuel module located next to the spare tire and they were known to go bad or is this what you are calling the relay.
Usually you can tell they are bad by looking at them due to the corrosion.

 

[N80]

I could not find such a module on my 03, at least not anywhere near where it is on the 04. None of the 03 and earlier diagnostic work ups have mentioned that module. So not sure if there is one on the 03. Anyway, once the bed is off I track down anything and everything connected to the fuel system. The fuel pump relay switch is in the fuse box. It was like $3 on line so I have one on the way along with a fuel filter and fuel line disconnect tool.

Have had a hard time finding a 1/2" drive T50 torx impact drive for removing the bed. Lots of people break the standard (non impact) ones. None of the local stores including auto parts stores, Northern Tool, Harbor Freight have one in stock locally. I hate (HATE!) Amazon and Chinese tools but I ordered one. Not sure it will be any stronger or better than a non impact one. We'll see.

 

[LittleBill21]

I could not find such a module on my 03, at least not anywhere near where it is on the 04. None of the 03 and earlier diagnostic work ups have mentioned that module. So not sure if there is one on the 03. Anyway, once the bed is off I track down anything and everything connected to the fuel system. The fuel pump relay switch is in the fuse box. It was like $3 on line so I have one on the way along with a fuel filter and fuel line disconnect tool.

Have had a hard time finding a 1/2" drive T50 torx impact drive for removing the bed. Lots of people break the standard (non impact) ones. None of the local stores including auto parts stores, Northern Tool, Harbor Freight have one in stock locally. I hate (HATE!) Amazon and Chinese tools but I ordered one. Not sure it will be any stronger or better than a non impact one. We'll see.

I strongly recommend you buy this. I use to break bolts constantly with my impact, this has been over 80% successful if you can get the air tool in there. it provides a shock to the entire bolt and not just the head.

https://www.amazon.com/Mayhew-37315-8-Inch-Pneumatic-Breaker/dp/B008M23A5U?dchild=1&keywords=shake+and+break&qid=1620703561&sr=8-7&linkCode=ll1&tag=ast45-20&linkId=a6648d081102c82f35fbae45e60d1cb7&language=en_US&ref_=as_li_ss_tl

Amazon.com: Eastwood Air Impact Screw Buster Remover with 3 Phillips Bit Heavy Trucks : Tools & Home Improvement

Buy Eastwood Air Impact Screw Buster Remover with 3 Phillips Bit Heavy Trucks: Impact Drivers - Amazon.com ✓ FREE DELIVERY possible on eligible purchases

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[brokeasajoke]

I could not find such a module on my 03, at least not anywhere near where it is on the 04. None of the 03 and earlier diagnostic work ups have mentioned that module. So not sure if there is one on the 03. Anyway, once the bed is off I track down anything and everything connected to the fuel system. The fuel pump relay switch is in the fuse box. It was like $3 on line so I have one on the way along with a fuel filter and fuel line disconnect tool.

Have had a hard time finding a 1/2" drive T50 torx impact drive for removing the bed. Lots of people break the standard (non impact) ones. None of the local stores including auto parts stores, Northern Tool, Harbor Freight have one in stock locally. I hate (HATE!) Amazon and Chinese tools but I ordered one. Not sure it will be any stronger or better than a non impact one. We'll see.

It just hit me, yours probably does not have a driver module. 03 was last year of Trition truck and that was a change introduced to the 04 model.

 

[Alan W.]

Same here. I was thinking it was an 04 not an 03.
I think the modules started with the 04 year.

 

[N80]

I got off work at noon today and headed down to the cabin. Got the bed off the truck in well under an hour. If the bed bolts are not rusted/frozen it is simple. One bolt was a little tough but PB Blaster loosened it up in no time. Used the FEL to lift it off the truck. With a tractor the size of mine and me being the only hand I would not recommend this approach for a nice looking daily driver. As is, my bed is already beat up and scratched up so it was no big deal.

I am glad I took this approach because getting the skid plate off and loosening the tank straps was much easier working from above and made getting PB Blaster on the bolts easier.

Getting the fuel lines off was still a miserable experience. They have little plastic clips (not the kind that there is a tool for) and the connection was under the cab in the frame rail. Could barely get my hands in there. Couldn't see. That alone probably took 30 minutes. I probably could have loosened the tank straps and made some more room which is what I should have done. I just couldn't tell how much play the lines had in them.

After that I just put cribbing under the tank and loosened the tank straps. The tank was about 1/3 full and plenty heavy but manageable with the cribbing. I just slid one piece of cribbing out at a time alternating ends until it was on the ground.

At this point the bed is off and tank all the way out. The whole thing, including clean up and getting the gas out of the tank (no small feat) took less than 3 hours. I don't think that was all that bad single handed.

Glad I took the bed off. That part was easy and made access to most everything much easier than working entirely under the truck. I'm too old for that.

Will buy the whole pump/sending unit and come down next weekend to put it all back together.

If it doesn't work after that I'm pushing it over a cliff.

 

[N80]

A general fuel system question. Does the fuel system need to be bled when all of this gets put back together? If so, how? I know there is a little valve on the fuel rail over the injectors.

 

[Alan W.]

I never had to bleed one that I replaced the fuel pump on. They arent like a diesel. May take a couple of cranks but she will purge the air snd fire up.

 

[N80]

Thanks!

Here are a few pictures of this adventure

 

[Alan W.]

Cant understand why fuel pumps cant be mounted on the frame rails and accessible.