smithrock
Long Beach, CA.
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Joined: 01/07/2005
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I need to replace my fuel pump which is located in the tank, how difficult is it to remove and do this job? I called a shop and they wanted $700.00 to do it! He said the part alone was $450.00 I've been looking online for replacements pumps and they range anywhere from $90-$450 !!!!
I need to do this myself to save money for camping! Any insight would be great!
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donn0128
Pronounced Ore-gun
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Joined: 04/21/2005
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My personal suggestion? Go to your auto parts store and buy a quality after market frame mounted electric pump and also get a high quality fuel filter. Drop the tank, being extremely careful gasoline is flammable, and you don't want to burn yourself up. Drop the tank, get rid of the in tank junk. and simply install a pickup tube to replace the pump. Then before you reinstall the tank, find the power wires to the pump and disconnect then to run to the new fuel pump. Did it on a Ford van that I once had. No more fuel pump problems for the large tank. Was going to do it to the aux tank if necessary, but that one never died so never did.
Fuel tanks can be very heavy, depending on the amount of gas left in it, and are always awkward to handle. You will need one or two floor jacks and another body to help you
Donn
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GMT
Chilliwack BC Canada
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Joined: 05/07/2006
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Greetings. Suggest that you try the Z71 Tahoe/Suburban form (Google it and sign in) It seems that several of the regulars are GM mechanics and post some good info when problems or questions are posted. Also if you always run with the tank over 1/3 and 1/2 full pump will stay cooler and last longer ...That I am Told. Hope this helps... Cheers Grant.
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rjcalif
Garlic Capital of the World - Gilroy, CA
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Joined: 10/20/2003
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It's not very hard to remove and replace. The entire job can be done in 3-4 hours by someone with decent mechanical skills. If you search the web you'll find a few sites with step by step instructions.
Just so you know, the in the tank fuel pumps are prone to failure if you drive often with less than 1/4 tank of fuel. The fuel in your tank is used to cool the pump. Given the current fuel costs I'll bet more and more folks run their tanks nearly dry before filling up.
RJ.... + wife + 2 teenage boys (13 & 15) + 2 dogs (1 big & 1 small)
2000 American Eagle 40DS and 2000 Suburban 2500 4x4 aka: super toad (looks small.. don't it)
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GMT
Chilliwack BC Canada
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Donn0128 - Good info - Problem is that the pump and fuel gauge sender are all attached together. Grant.
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smithrock
Long Beach, CA.
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Joined: 01/07/2005
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GMT wrote:Donn0128 - Good info - Problem is that the pump and fuel gauge sender are all attached together. Grant.
Thanks for the info Donn0128. And like Grant said, fuel gauge sender is attached along with the sensor and everything else for that matter. Can I do without the sender and sensor? And just go with a frame mounted pump?
If anyone does have those instructions on how to remove the tank and pump, and wouldn't mind posting it, that would be great.
Well, I guess I know what I'm doing this weekend 
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smithrock
Long Beach, CA.
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Joined: 01/07/2005
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GMT wrote:Greetings. Suggest that you try the Z71 Tahoe/Suburban form (Google it and sign in) It seems that several of the regulars are GM mechanics and post some good info when problems or questions are posted. Also if you always run with the tank over 1/3 and 1/2 full pump will stay cooler and last longer ...That I am Told. Hope this helps... Cheers Grant.
I'll check that out too--thanks!
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sum1
So-Cal
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Joined: 11/07/2005
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Just dig in and do it. It's pretty straightforward and easy especially if the tank is nearly empty. You may need to have someone show you how to remove the quick-disconnect fuel lines. They make a tool for it,but I just pinch and pull. The pump/sender has a bayonet type retaining ring, IIRC. Buy the best you can find so you don't risk doing it twice. I've had brand new, cheap, auto parts store pumps fail.
BTW, I run mine til almost empty - I'm willing to risk the pump rather than carry 10 gallons of fuel I'll never use.
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Berticus
Boise, ID
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Joined: 04/06/2001
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I replaced the fuel pump in My wife's 99' Tahoe and it took me about 3 hours(1 1/2 yrs ago). Make sure you buy the pump, new inline filter and the special fuel line fitting tool(you really need them, I bought the 3 set tool, filter and pump for about $225).
I 1st took out about 20 gals of gas (she filled up the tank about 2 days before pump went out).
2nd - disconnect the battery
3rd - jack up the Tahoe as high as you can(this will give you much needed room, I was able to use 4 jack stands).
4th - remove the fill hose from the rear of the tank.
5th - Have jacks or other support for tank. I used a small floor jack with a 2x6 board. Then start taking the tank bolt/straps off. (my straps were bolted on one side and anchored through a slot on the frame. A real pain to get off).
6th - lower the tank a bit and now you can get the
a. - elec. connection to unplug
b. - vent hose, inline fuel line to use the tool.(I had 2 different sizes)
7th - make sure you have not forgot anything else.
8th - lower the tank all the way to the ground and away from the Tahoe. At this time before you remove the pump, clean the area of the pump and get most of the gunk out as when you lift the pump out you do not want any of it inside your tank. remove the pump - remember how it was and in what position(my pump was screwed on -sort of- and had to hammer/flathead the thing a bit to remove it) Quote Sum1 "The pump/sender has a bayonet type retaining ring, IIRC."
9th - put in new pump
10th - install new inline fuel filter on the inside of the frame rail.
11th - install tank in the opposite order.
I hope this helps out, Robert.
The Setup:
96' Serro Scotty 25' 4x4, Diesel, Class-C(pic coming), 86 20' Chris Craft LTD,69 Wife,02 1st Son,04 2nd Son,2 dogs (Yellow Lab & Border Collie).
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smithrock
Long Beach, CA.
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Joined: 01/07/2005
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Thanks alot, Robert!
This tool your talking about, whats it called or where did you get it? It's the one that you use to disconnect the hard lines that go into the tank?
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