Engine/Transmission (1998.5 - 2002) In Tank Fuel Lift Pump Replacement

[RMHanes]

A few years ago was "forced" into having the engine mounted fuel lift pump replaced with the in tank upgrade. Was just about to install a FASS system when this happened. Have a '98. 5 2500 5 speed with about 130,000 miles and truck is in stock condition. Readiing and evaluating replacement of the VP44 fuel pump and will probably purchase from Blue Chip Diesel. This is because of reading about sudden failues of the pump where it stops and need to have the truck towed. If do this would also like to install a FASS fuel pump and filter so have easier access for fuel filter replacement and more importantly good fuel supply pressure to the new VP44 pump. Does the intank lift pump need to be removed? Is it best to drop the tank or jack up the bed? What replacement hoses and electrical connections need to be modified?

Thanks for any suggestions and tips on doing this replacement.

 

[Cosmo]

A buddy of mine is running a holley blue (I think) frame mount lift pump that sucks through the in-tank pump with no problems. Most people recommend removing it though.

 

[Adubya]

I bought a fuel sump from Alligator Performance and installed that and ran a hose to the frame mounted pump and just left my in tank pump in there so the fuel level sending unit still worked. The sump ran me around $160 but was more than worth it because it pulls fuel from the bottom of the tank and it much easier on the pump.

 

[Gary - K7GLD]

I've been using the Walbro setup pictured below for about 8 years now, with no problems - PSI stays at the 16 PSI or so seen on the gauge, and only drops about 2 PSI under heaviest load - PSI sensor is immediately before the VP44. I also fabbed up the one-way bypass valve seen on the Walbro, to allow full flow of fuel AROUND the Walbro in case it fails - which would then otherwise cut off all fuel to the VP44:

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The other pump seen in the line, is a Carter 15 PSI pump that is also bypassed, and serves as purely a backup, in case the Walbro fails - it is disconnected from power, but a simple single wire connection will get it going if needed - hasn't been needed so far...

 

[jeepit]

RMHanes,
You can get a Draw Straw Kit from Vulcan Performance, pull the fuel module and remove pump and replace with Draw Straw and reinstall fuel module. Make sure to get the kit for the intank pump. You will have more than enough fuel being pulled form tank.
I took the bed off my truck when I did this install. Much easier to work on plus I was having 1/4 tank issues so I was not sure the amount of fuel in the tank at the time I did this procedure.

 

[RMHanes]

Thanks to all for the information. Completely forgot or overlooked the fact that the pump may have to stay in so can still use the fuel gage. Jeepit; how hard was it to get the bolts loose to remove the truck bed? Did you remove it completely or just lift up one side? Thinking that there would be a few wires to be concerned about. Other than that the bed option sure is better, do not need to crawl on ground and have extra person or jack or something to suppor the tank. Moving the fuel filter to the frame will greatly increase the accessibility for changing filter. Had seen in the Geno catalog that a heater option is available also.

 

[jeepit]

RMHanes, The pump is in the fuel module with the float hanging on the side of the module. Taking the pump out does not affect the float. Taking the pump out allows for full fuel flow. It was really easy to convert the module with the parts from Vulcan and I suggest you check this option out. As I stated before I had the 1/4 tank issue and this cured it for good.
Two of the bed bolts were a b. itch to get out... . the others were easy. I had 3 other helpers to get the bed off. Bed was lifted towards rear of truck where I had a combination of sawhorses and 6x6 blocking. The front of the bed was held in position with more blocking.
The whole job took about 3 hours. (had to run for a part)
I already had the AirDog pump with all electrical and plumbing hooked up so the job was just switching the old module out and hooking fuel and return lines.

 

[Adubya]

I had the vulcan draw straw and switched to the ADP Sump because I kept running it out of fuel when going up steep grades and hills. (I use my truck a lot off road)

http://www.alligatorperformance.com/diesel-fuel-sump-tank-drop-required-p-7952.html

 

[jeepit]

I had the vulcan draw straw and switched to the ADP Sump because I kept running it out of fuel when going up steep grades and hills. (I use my truck a lot off road)
http://www.alligatorperformance.com/diesel-fuel-sump-tank-drop-required-p-7952.html

Did you have the draw straw in a fuel module?
My truck is never at an incline that steep.