Any tips on replacing the fuel pump?


RustyCage

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This is on my list to do. I've watched several YouTube videos. Pretty straightforward. Most recommend replacing the entire fuel pump assembly. You disconnect three connections under the Jeep - electrical connection, fuel line and breather (?). Place floor jack under gas tank. Remove seven bolts and drop tank. Trickiest part appears to be removing the big threaded collar that holds the pump in place in the tank. Disconnect and remove old pump. Insert and connect new pump. Reinstall collar. Lift and bolt up tank. Reconnect electrical, fuel and breather lines. There are a few other details like properly aligning the pump in the tank and it's also a good time to flush and clean the tank while you have it down (not sure of the best method for this). Watch a couple of YouTube videos and it'll be pretty clear what's involved. A buddy and I are going to do both our TJs at the same time so we can help each other out.
 

Chris

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It's actually not hard at all. Dropping the tank isn't that hard to do. I did it on my own in a matter of an hour or two at most, and that was the first time.
 
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Daryl

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It would be the perfect time to perform the rollover valve mod while you have the pump out.

 
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Rob5589

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Make sure the tank is empty, or as close to as possible. I did mine with a floor jack but a trans jack will be better. Lower it slowly so as not to break any lines. Replace all the bolts with stainless steel while you are there.
 

Matt77

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I've done it on my chevy work van. Couple tips are make sure you have enough clearance. In the case of van I had to jack up all 4 axles on jack stands to get enough height to drop the tank. Like the other guy said try not to have any gas in it. Getting the pump out is the easy part. The hard part was disconnecting the stuff above it. The pump will pretty much line itself up. I think it screws in. Don't be a cheap ass buy the whole thing don't try to fix it. And if you use a floor jack use like a piece of plywood to support the tank. Well atleast in the case of my work van gas tank is huge and the small cup would put too much pressure in one spot on the tank and possibly crack it. You got this! But should have a friend with you just in case you need a hand.
 

Yams

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I concocted this thing to help stabilize the gas skid/tank when I lowered mine, just used some standard wire shelving I had lying around and unbolted the saddle and bolted it back on top of the shelf wiring. Worked pretty well!

Just to parrot the above, try to get the tank as empty as possible and lower it SLOWLY. Those rollover valves are easy to break...

IMG_20180622_211040.jpg
 

Antithetical

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I concocted this thing to help stabilize the gas skid/tank when I lowered mine, just used some standard wire shelving I had lying around and unbolted the saddle and bolted it back on top of the shelf wiring. Worked pretty well!

Just to parrot the above, try to get the tank as empty as possible and lower it SLOWLY. Those rollover valves are easy to break...

View attachment 49521
I literally did this last night, and I just saw your pic while checking on steps to drop tank one more time. Great minds think alike! Haha.
20200916_142233.jpg
 
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AjRagno

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I replaced the fuel pump in my ‘05 LJ a few months ago. The ‘05-‘06 TJs are a little different than earlier models.

You don’t have a Schrader valve so you’ll need to remove the fuel pump relay and run the engine till it dies. Probably need to repeat this step a few times but still expect fuel to spray out when you disconnect the lines.

The fuel line connections are on the driver side, above the rear axle, next to the frame. No tools are needed, simply pinch the retainer and pull the lines out. You’ll also want to pop the wiring harness retainer out of the skid while you’re there.

The fuel pump and vent valve are both located at the rear passenger side of the tank. You’ll need to lower the tank to reach the connections.

For the anti splashback valve, just reach in and pop it off. I didn’t do anything more than rub each tab against sandpaper. When it freely slides in the housing, you’ve removed enough material.

I had less than 4 gallons of fuel in the tank and it was still a bear to get lined up on the re-install.

I’ve seen it advised to remove the wheel well liners. If you do, you’ll need to replace the body clips.

https://www.amazon.com/gp/product/B0017UBHQS/?tag=wranglerorg-20
 

jeepins

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I feel there are two things that could possibly be a PIA about replacing the fuel pump:
1. Dropping the tank.
2. Removing the fuel pump retaining ring.
The rest is easy.
 

Jerry Bransford

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I feel there are two things that could possibly be a PIA about replacing the fuel pump:
1. Dropping the tank.
2. Removing the fuel pump retaining ring.
Removing and replacing the retaining ring is easy with a big strap wrench. Be aware that most strap wrenches are not big enough but but they're available. I found mine in the plumbing dept. of Home Depot, they were too small in the tool department.
 

AndyG

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Fuel pump went out in my suburban years back....I had just filled the 40 gallon tank :mad: Talk about SUCK!
There is some degree of thought that fuel pumps that are about to go out tend to do it when a tank is just filled.

I got hit in the rear end filled the tank up about an hour later and my fuel pump immediately failed.

I found an ATV Jack was really handy for this job.

Also be sure to remove the little rubber thread protectors on the strap nuts at the rear before you start loosening the bolts or you will break them. Trust me.