HI all. I dropped the tank today and replaced the pump. I will highlight some of the gotchas. If you have any specific questions, just post and ask!
When I first bought the van, for maintenance purposes, I had a shop replace the pump. The Spectra Premium I bough only lasted 32 months - grrrrr.
This job is only an advanced level job. Heck, even a novice could get through this one.

Here are the symptoms that lead to failure:


Rough idle. Not horribly rough, but at times jittery.
Then for the last 2 months, I would randomly get a cylinder drop at idle. I felt just like a bad plug wire. It had done this 6-7 times.
Then it started to whine a little.
After that I had my failure. I backed out and the engine just died. I thought "OK, which is it - CPS, PCM or Fuel Pump?"
So I checked for codes - none.
Then I check for spark - flash flash flash - no worries there.
Then with the key on, I pressed the Schrader valve on the fuel rail - drip drip drip. Yep no pressure - bad fuel pump.


So today I dropped the tank. First I ran the tank to the point that the gas light came on. I put my van on ramps which gave me plenty or room. I got two jack stands and put them under the tank, but not touching, more like 8 inches down. I undid the first j-strap to the last thread. Then I did the rear j-strap to the last thread. Then I unbolted both and eased the tank down in a bench press style on to the jack stands. I undid the vapor lines (there are two, one on the front, one on the rear. Then the electrical connector (it is a standard latched connection) and then the fuel line (which uses a squeeze style quick connect. If you fingers are strong enough, just squeeze hard and it will come off).


Note: remove the j-straps totally. They get in the way for the rest of the job. They just turn and fall out.


At this time, I found two handles on top of the tank. I held one handle and removed the jack stand. Then put that side of the tank on the ground. Then I did the other side the same way.


Then I slid the tank out from under and had to deal with the lock nut. Mine was on tight! I didn't have 'the tool' so I began to improvise. I tried ot use my hands - no workie. Then I tried a flat head screwdriver - don't do this haha. Then I got a rubber mallet. Walllahh! A few strikes on the nut's nubbies got it going and then I was able to unscrew it by hand.


I pulled the old pump out and then using a hand pump, got the last 5 or so gallons out. Then I began to install the new pump. NOTE: The new gasket is already installed on the pump. Move the gasket down 3 or so inches down and install the gasket on the tank FIRST. Then press the pump into the gasket. I wasted about 30 minutes trying to put both in at the same time LOL.


I put the nut on, and it has a tendency to cross thread when you put it back one. I ended up screwing it on and then pressing it on it. It clicked and then I was able to screw it down.


Installation is reverse of removal. NOTE: install rear j-strap first before installing the front.


It's great to have this done! It took me about 3 hours with my wife helping. We took our time too.

 

Which is it, only an 'advanced level' or one that a 'novice could get through'?

 

Yea that did sound funny LOL I was tired bro!


It is an advanced level job as in there is a lot of muscle work involved but a novice could get through it if he took his time and was good with tools

 

This is awesome; good to know this is up here. have wondered about how to do this should I ever need to- thanks for posting.

 

With 185K miles on my '01 5.2 3500 extended Ram van, I am wondering if this should be done as a preventive measure? I typically only drive my van long distances, just getting back from over-wintering in FL while pulling my 20 foot TT.

Knock on wood, it is running great after just putting 3900 miles on it since January. Previous owner used it every day in his work and kept it in the garage. I've owned this van since it had 130K on it. I've replaced the tranny, the rad, brakes and hoses, drained and refilled all fluids, new wires, plugs, belts and hoses, O2 and a few engine sensors. I have cleaned electrical grounds and used Deoxit on many connectors. I added air bags to the rear to hold my 500# tongue weight, which has worked well on this extended van.

I am a proponent of "if it's not broke, don't fix it"... but I hate the thought of being broke down out of town pulling a TT. I typically travel with a full tank of gas, and rarely leave the van sit with less than a half tank.

So, what does everyone think about replacing my fuel pump... or should it last another few years?

 

Well sometimes when electrical motors die - they give no warning...


It would be good preventive maintenance.


BTW -- about dropping the tank --


you need a gear wrench. A deepwell socket will not fit and it would take 30-40 mins per nut if you use a regular open ended wrench...

 

Did a Ford 500 fuel pump today.

You'll be pleasantly surprised to know ( should you choose to buy one ) they put a big rubber seal in the floor plan for this purpose. Simple 20 minute swap, no issues. Wish they'd thought that far ahead on these Dodge vans eh

 

im too mopar prone to buy a ford just for that luxury---sorry-did my fuel pump 5 yrs ago

 

My last vehicle was a 02 Lightning. The pump in that truck is the same as the van.


Besides, if they make it that easy to change, then the probability of failure must be pretty high LOL


I went 160k miles on the OEM pump, then the second cheap, probably Chinese POS, went a whopping 19k miles.


Actually, the next time I have to drop the tank and do the pump (hopefully I wont have to) I am sure I will be able to do it in less than an hour.
In reality there is only 3 nuts, 2 clamps and 3 quick connect disconnects (which don't require any special tools) to take off to do the while job.

 

I had to replace my fuel pump just off the side of the road In Baja at a farmer's casa who helped me. I had ~ 25 gallons in the tank when it failed, and now way could I have done it without his help or tools, mainly the jack, a spare tank to siphon off the fuel, and some deep well sockets.

He drove to into Ensenada to get me a new pump and it cost 90$ for the pump and another $25 for the Sock filter which fit on the ned.
I think it was a Carter brand, and I have about 25K miles on it.



I was back on the road heading south within 12 hours of pump failure. I gave him 40$, a cordless Ryobi drill with charger and 2 batteries, a headlamp, and a folding campchair and a camouflage tarp. Well I kind of forgot about the campchair and tarp but was glad I did.