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Well, she started right up and ran well. I have been up for over 24 hrs. so I will finish putting her back together tomorrow. I'll take her out for a drive to be sure everything is up to snuff. Thanks so much for helping me figure this out, Hey You!! I have some other work to do starting next weekend and will be sure to create new topics for the repairs.
The hardest steps in this repair were:
Getting the new seal to seat all the way into the gas tank. That took some finagling.
Getting the lockring to thread back on was also tricky and took some time as well.
Finally, my hands hurt so time for a naproxen and coffee. That should fix me up just fine.
Skip the coffee. Just go to bed. I have found that there is nothing a few hours of unconsciousness can't help.
Skip the coffee. Just go to bed. I have found that there is nothing a few hours of unconsciousness can't help.
Yep, I did just that. I got up today, had lunch with my girlfriend, put the truck back together. Then, I started her up and she purred like a kitten. I put all the tools away, put the jack stands away, got my wallet and house keys and heard the truck shut down. I walked up to her and I could hear the ASD relay, chattering away. One down, one to go.
The truck is finally running and I feel confident that I have identified the fuel and the electrical problems. It's kind of tough having two at once. Anyway, the fuel issue was definitely the pump. The electrical issue was a grounding problem, common enough on these vehicles.
The problem was staring me right in the face. I managed to get the truck running a couple of times today, but then it would shut down and the ASD relay would chatter. I started going back through the electrical system, particularly the grounding, because I was still reading 10.5 VDC on the ground pin of the ASD relay, meaning the PCM couldn't pull the relay to ground to give enough voltage/current to hold the relay.
It was starting to cool off and get dark and I had already gone through all of the ground connections, reseating several. Finally, while trying to think, I just started wiggling ground wires and as soon as I got to these, the chattering stopped, then started again. I wiggled them again, the chattering stopped, I started the truck, the relay started chattering and the truck died. I had found my problem.
You see, I had given this truck to my parents to use for about three years and they had some problems with it, similar to mine. Their mechanics replaced the PCM, installed a new battery terminal clamp, like the ones you get from Autozone that clamp on the bare wires. Those are meant to be temporary. I had replaced that several years ago when the truck was acting up. Well, I didn't think that they may have replaced some of the other factory connectors, trying to solve a ground problem just like me. This is what I found. I have made a temporary repair until I can get some good connectors and solder them up. One of these conductors is the PCM ground. I have the 5.2 engine and these are grounded to the alternator bracket at the front of the engine, battery side.
I have found that there is nothing a few hours of unconsciousness can't help. 
