Powerstroke fuel pump replacement tragedy?

   / Powerstroke fuel pump replacement tragedy? #11  
Glad all turned out well.:D

For me I usually get to the broke stage and it's quickly downhill from there!:eek::eek:
 
   / Powerstroke fuel pump replacement tragedy? #12  
I absolutely hate it when these simple little 20 minute mechanic jobs turn in to 20 hours of frustration!!!

Glad to hear you were able to take care of it quick and effectively.
 
   / Powerstroke fuel pump replacement tragedy? #13  
I absolutely hate it when these simple little 20 minute mechanic jobs turn in to 20 hours of frustration!!!

Uhh, did I tell you about when "She Who Must Be Obeyed" went to change a burned out light bulb on the front porch?:D:(
 
   / Powerstroke fuel pump replacement tragedy? #14  
Wow, haven't heard of that happening, but LOTS of people have dropped the little pushrod into the engine internals...
Hardest part when I changed the fuel pump on my 96 was getting that dang big fine thread banjo bolt on the back started back in without cross threading it...
 
   / Powerstroke fuel pump replacement tragedy? #15  
I'm about to do the same job. My Fuel filter canister had two pin hole leaks of which I fixed thanks to Mr.JB Weld. Can you tell me what kind of wrench did you used to undo the banjo bolt behind the fuel pump without removing the turbo bracket.Thanks Just Dave
 
   / Powerstroke fuel pump replacement tragedy? #16  
Oh Yeah, Will Natural Lite work when I break Something?
 
   / Powerstroke fuel pump replacement tragedy?
  • Thread Starter
#17  
I'm about to do the same job. My Fuel filter canister had two pin hole leaks of which I fixed thanks to Mr.JB Weld. Can you tell me what kind of wrench did you used to undo the banjo bolt behind the fuel pump without removing the turbo bracket.Thanks Just Dave

The photo is the wrench I used to undo the banjo bolt. A 3/8 drive air ratchet with a short flex extension and socket and adapter.
 

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   / Powerstroke fuel pump replacement tragedy? #18  
I too am about to tackle this job on my '96. Except, I don't have a drip. I have ALOT of fuel pouring down my bell housing when the truck's running. And being a 5-speed, I could do without my clutch getting wet. Other than the fuel line itself being bad, I suppose it's gotta be the pump.

This has been an awesome thread.
 
   / Powerstroke fuel pump replacement tragedy? #19  
The photo is the wrench I used to undo the banjo bolt. A 3/8 drive air ratchet with a short flex extension and socket and adapter.

One would do dickall with that itty bitty air ratchet on the one i did last year.Took a big *** combi wrench to crack that bolt loose.
I wouldn't wanna own one of these 7.3 contraptions if the gave it to me,what a PITA to work on:mad:
 
   / Powerstroke fuel pump replacement tragedy? #20  
I too am about to tackle this job on my '96. Except, I don't have a drip. I have ALOT of fuel pouring down my bell housing when the truck's running. And being a 5-speed, I could do without my clutch getting wet. Other than the fuel line itself being bad, I suppose it's gotta be the pump.

This has been an awesome thread.

There are other possibilities....I just replaced the filter restriction sensor on my 96 because it was leaking.
Another possibility is the filter canister itself sometimes corrodes through when people don't drain the water often enough. It is a very expensive part.

I just replaced my pump for the second time a month ago...my hands stilll haven't completely healed up from all the scratches and gouges. I'm almost to 200,000 miles. OEM pump leaked at around 80,000, its replacement made it to 195,000 and fortunately it had a lifetime warranty from Autozone...sadly they don't do that anymore, guess they found out some people keep a diesel pickup a long time.:)
 

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