Fuel Pump NIGHTMARE!!!! - Ford Powerstroke Diesel Forum
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Old 02-03-2008, 01:32 PM
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Fuel Pump NIGHTMARE!!!!

Well, yesterday I changed the fuel pump on my 96. Things were going pretty well, the banjo bolt wasn't much of a fight with the turbo in, other fuel lines seemed not too bad with the fuel bowl unbolted. Unbolted the fuel pump, and progressed to rock and wiggle the $%^& thing out of the bore in the block (all the while worrying about the tappet falling in as is roumored to sometimes happed.) The pump came up about 1/8-3/16" and didn't want to pull out, I must have put a little too much off-angled prying on it, then I heard a *CRACK*. The pump pulled out!!! but then I noticed the tappet, sleeve and o-ring were still in the bore of the block!!! After trying to fish it out, it actually dropped down to sit on the cam, and seemed to be too tight to pull out. After whimpering for divine forgiveness, some WD-40 and a lot of fighting with needle nose pliers, I was saved.
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Old 02-03-2008, 03:34 PM
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I am glad you got it out I could only imagine the horror!!!


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Old 02-03-2008, 04:18 PM
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Dang when i did mine a while ago i was scared of the same thing but luckily the tappet stuck to the pump real well and pulled out too. Thank goodness you got that thing out!!
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