Returnless fuel pump sending unit

[MrFord]

My 2000 SVT' fuel pump is on it's last miles I think... it started bucking and stalling a couple weeks ago with the heat wave that hit us. Either I'm lucky or something else is wrong, but after letting it cool down, it works fine for a while.

Not wanting to take any chances (AAA is nice but still better not to get stuck in the middle of nowhere), I decided to bring it to a mechanic to see if he would replace the fuel sending unit before it completely dies. But since the car was still running, he didn't want to do anything on it. Fine I said, and I dropped it at the Ford dealership on my way back.

They did run tests, acknowledged that the fuel pump was dying, then said something about the fuel pressure monitor sensor too, total close to $1200. I said fine, it's expensive as hell, but since they seems like the only ones who can swap the sender unit, and even if I had my doubts about the sensor, they're the Ford guys, right?

Well after a week at the shop, I stop by to pick up the car, and surprise, nothing had been done to the car. Nothing at all. The guy forgot to call me back to tell me that the fuel sensor was BO. And the sender unit too. Told me to call him back Monday. I told him to just get the sender unit, and forget about the sensor, that I was pretty sure it wasn't a problem, especially for the extra $400 they wanted for it, parts and labor.

Well, now it's Monday, and not only they didn't get the parts, they don't even know if they'll be able to get it this week, or at all. Now they were offering to use a sender unit from an auto part store, for $550, instead of the already outrageous $450 they wanted for the Ford one. I told them to forget about all this, and I will come pick up my car tonight, and whatever happens happens.

Long story short, what can I do now? The car still runs, I just don't know for how long, but when it does die, what are my options, if Ford can't even get their hands on their own parts?
Anybody knows about that sender unit that the auto parts sells? I made sure with the Ford guy that he wasn't talking only about the pump, and that the main problem was the filter.
Any of you guys had to look for that part recently and had the same problem?

I'm not that gifted with mechanic skills, my tank is almost empty, so it's not too bad to work in it, but I don't have the tools/talent/space to drop the tank/hack the floor. I know it takes that tool to install the revised sender unit, so has anybody had any luck with mechanics (not dealers) being able to fix it?

I don't use my car a lot, I take the train to work, but I don't feel like leaving the car at the dealership for a month or 2 until they get their hands on the darn pump.

 

[striker2]

there are no special tools required and there is no need to drop the tank to install the revised sending unit. call up Steve at Tousely (or send him a PM on here FORDSVTPARTS is his SN I believe) and he should be able to get you the sending unit for a lot less than the your local stealership wanted.

to install it, remove the rear seat bottom, remove the rubber plug and disconnect the wiring harness, then start the car and let it run till it dies. then using tin snips, cut slots towards the rear in the floor around the hole so that you can bend the pieces up and make the hole big enough to pull the sending unit it. disconnect the fuel line (squeeze the tabs and pull, if it wont go push on the line before you squeeze the tabs and it should pop off), make sure you have some paper towels handy to soak up any fuel that may come out. then use a flat head screwdriver and a hammer and working around at each of the tabs, remove the lock ring. pull the complete sending unit out and set aside.

to remove the locking ring in the tank, reach down and cut the 4 black tabs using a razor blade (the square scraper blade style works well). they are just plastic so with some wiggling and pushing they cut fairly easily. once you have those tabs cut off, remove the ring from the tank. set the new gasket down into the groove, it might seem a little too big, but it does fit properly. then you can carefully set the new sending unit into the tank, install the new lock ring (tapping it into place with a screwdriver and hammer), connect the fuel line, bend the tabs back down as flat and smooth as possible (some people like to tap them down so that gas fumes dont enter the car but the gasket on the sending unit is supposed to prevent that anyways). hook up the wiring harness and start the car (before you put the back seat back in just in case something isnt right). if everything works and fuel isnt leaking anywhere, put the back seat back in and go back to enjoying your car.

 

[marvinstockman]

If car runs well with a full tank of gas, then it is probably a clogged fuel filter in the fuel pump assembly. It needs to be removed and the internal vertical filter cleaned, or just keep the tank full.

 

[MrFord]

The problem is that the car acted the worst with a 3/4 full tank, and it happens randomly. I ran it down to almost empty and it ran perfectly.

Good thing is, I was looking at Team Ford in Las Vegas, and they can have the Ford OEM assembly for $330, and there's also a couple replacement brands for 220-300. Since the OEM part is back order, I have to call them to check in until they can get it back in stock before I can place the order.
The car still runs, so I'm just crossing my fingers it can run long enough for me to get the part, if not I guess I'll have to settle for the replacement one.

 

[hetfield]

You can get the whole returnless fuel pump assembly from Rock Auto; both Carter and Motorcraft. Motorcraft is about $330, and the Carter part is around $220 (so about the same price as Team Ford). Might be worth a call to see if they have any around. I have to do this same job on my 2000. I was hesitant about the non-OEM part, but after talking to some people I learned that Carter is a well known name in fuel delivery.

then start the car and let it run till it dies.

Hey Dan, what if the pump is so far gone that it won't start/run? My car is sitting at PRT and the last time Pole had to move it he said it ran really bad. For the record, the car is on it's fourth fuel pump.

 

[BrApple]

if it won't run or start then chances are there isn't any fuel pressure. alternatly you can just release the pressure at the valve on the fuel rail.