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Scott
Scott, Driveability expert
Category: Dodge
Satisfied Customers: 1190
Experience:  Dodge,Chrysler,Jeep Master Tech since 92.ASE Master since 1990.Currently Dealer employed.
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How to remove and replace a fuel pump ina 1500 Ram truck

Resolved Question:

how to remove and replace a fuel pump ina 1500 Ram truck
Submitted: 6 years ago.
Category: Dodge
Expert:  Scott replied 6 years ago.
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Scott :

Hello, do you need a step by step or just and overview?

Scott and 6 other Dodge Specialists are ready to help you
Expert:  Scott replied 6 years ago.
Dont worry if my answer is not liked I will refund the money, I think you pushed the wrong button.
Expert:  Scott replied 6 years ago.

REMOVAL- EXCEPT DIESEL

Fuel Tank Draining

WARNING: THE FUEL SYSTEM MAY BE UNDER CONSTANT FUEL PRESSURE EVEN WITH THE ENGINE OFF. THIS PRESSURE MUST BE RELEASED BEFORE SERVICING FUEL TANK.

Two different procedures may be used to drain fuel tank: through the fuel fill fitting on tank, or using the DRB® scan tool. Due to a one-way check valve installed into the fuel fill opening fitting at the tank, the tank cannot be drained conventionally at the fill cap.

The quickest draining procedure involves removing the rubber fuel fill hose.

As an alternative procedure, the electric fuel pump may be activated allowing tank to be drained at fuel rail connection. Refer to DRB scan tool for fuel pump activation procedures. Before disconnecting fuel line at fuel rail, release fuel pressure. Refer to the Fuel System Pressure Release Procedure for procedures. Attach end of special test hose tool number 6541, 6539, 6631 or 6923 at fuel rail disconnection (tool number will depend on model and/or engine application). Position opposite end of this hose tool to an approved gasoline draining station. Activate fuel pump and drain tank until empty.

If electric fuel pump is not operating, fuel must be drained through fuel fill fitting at tank. Refer to following procedures.

  1. Release fuel system pressure.
  2. Raise vehicle.
  3. Thoroughly clean area around fuel fill fitting and rubber fuel fill hose at tank.
  4. If vehicle is equipped with 4 doors and a 6 foot (short) box, remove left-rear tire/wheel.
  5. Loosen clamp (FUEL TANK FILL / VENT HOSES) and disconnect rubber fuel fill hose at tank fitting. Using an approved gas holding tank, drain fuel tank through this fitting.

Tank Removal

  1. Loosen clamp and disconnect rubber fuel vent hose (FUEL TANK FILL / VENT HOSES) at tank fitting.
  2. Support tank with a hydraulic jack.
  3. Remove 2 fuel tank strap nuts (FUEL TANK MOUNTING) and remove both tank support straps.
  4. Carefully lower tank a few inches and disconnect fuel pump module electrical connector (FUEL PUMP MODULE CONNECTIONS) at top of tank. To disconnect electrical connector: Push upward on red colored tab to unlock. Push on black colored tab while removing connector.
  5. Disconnect fuel line at fuel filter / fuel pressure regulator (FUEL PUMP MODULE CONNECTIONS) by pressing on tabs at side of quick-connect fitting.
  6. Disconnect EVAP line at top of tank (FUEL DELIVERY COMPONENTS).
  7. Continue to lower tank for removal.
  8. If fuel tank is to be replaced, remove fuel pump module from tank. Refer to Fuel Pump Module Removal/Installation procedures

.

1 - BEZEL SCREWS
2 - FUEL FILL BEZEL
3 - HOSE CLAMPS
4 - VENT HOSE
5 - FUEL TANK
6 - FILL HOSE

1 - BEZEL SCREWS
2 - FUEL FILL BEZEL
3 - HOSE CLAMPS
4 - VENT HOSE
5 - FUEL TANK
6 - FILL HOSE
1 - BEZEL SCREWS
2 - FUEL FILL BEZEL
3 - HOSE CLAMPS
4 - VENT HOSE
5 - FUEL TANK
6 - FILL HOSE

 

1 - FUEL TANK
2 - STRAP MOUNTING STUDS
3 - VEHICLE FRAME
4 - MOUNTING STRAPS
5 - STRAP

 

 

1 - TOP OF FUEL TANK
2 - FUEL PUMP MODULE
3 - FUEL FILTER / FUEL PRESSURE REGULATOR
4 - ELEC. CONNECT.

 

1 - FUEL TANK8 - LDP FRESH AIR FILTER
2 - CHECK VALVE9 - LEAK DETECTION PUMP
3 - LIQUID EXPANSION CHAMBER10 - EVAP CANISTERS (2)
4 - FUEL FILTER / FUEL PRESSURE REGULATOR11 - FUEL TANK STRAPS (2)
5 - QUICK-CONNECT FITTING AND FUEL LINE (TO ENGINE)12 - CHECK VALVE
6 - EVAP LINE CONNECTION13 - FUEL PUMP MODULE LOCK RING
7 - LEAK DETECTION PUMP FRESH AIR LINE14 - FUEL PUMP MODULE

 

 

  • The plastic fuel pump module locknut (FUEL PUMP MODULE (TOP)) is threaded onto fuel tank. Install Special Tool 6856 to locknut and remove locknut (LOCKNUT REMOVAL/INSTALLATION - TYPICAL). The fuel pump module will spring up slightly when locknut is removed.
  • Remove module from fuel tank.
  •  

     

    1 - FUEL FILTER / FUEL PRESSURE REGULATOR
    2 - ALIGNMENT ARROW
    3 - TOP OF PUMP MODULE
    4 - LOCKNUT
    5 - ALIGNMENT MARKS

     

    1 - SPECIAL TOOL #6856
    2 - LOCKNUT

     

     

     

    The special tool is not needed, we use large chisle and hammer to turn the nut,

     

    Please reply ,

    Scott and 6 other Dodge Specialists are ready to help you
    Expert:  Scott replied 6 years ago.
    hello- looks like you accepted the question 2 times, did you choose to do this or was it an accident? I can refund one accepted answer . please reply, thanks Scott.
    Customer: replied 6 years ago.
    I'm not good with the computer...Please reund...what ever I did.
    Expert:  Scott replied 6 years ago.
    Ok- I sent a message to the boss to refund you for one of the questions. Are you ok with the info i sent?
    Expert:  Scott replied 6 years ago.
    You were refunded 14 dollars- the boss took it out of my tips.
    Scott and 6 other Dodge Specialists are ready to help you