yo,
Installation Lessons Learned
Source: by digitalbill
: If you decide to put in a cheap fuel pump, you are probably going to have to replace it within a year. Either spend the extra money on a really good one or, cut an access door in the bed.
2: Get the right tools for the job. Fuel line removal tools are very cheap and will save you hours of aggravation
3: If you decide to cut an access door, see if you can borrow a 110V angle grinder or an air operated one (if you have access).
I used my 18V ryobi and while it worked fine with the cutoff wheel, I have three batteries and, starting at full charge on all three, they all had to go back on the charger twice before I was finished cutting.
4: Speaking of cutting.. .I got the steps (measurements and stuff) from Steve83 site on SuperMotors site. It looked like he used a sawsall but he also has a body lift. I have the stock lift so I was scared to go too deep. I was right. the vent line is about 1 inch (if that) from the bottom of the bed. I didn't hit it but, that would have sucked.
5: Safety first. I kept a garden hose stuffed up on the top of the tank with it on "mist" to keep everything wet. I don't know if it helped or not but, no fires and there were LOTS of sparks. Eye protection goes without saying...
6: Taking the retaining ring off is easy. MIESK5 Nore; use a Brass drift/punch so there are no Sparks
Putting it back on? Not so much. I bent the "starter" tabs at just a little bit of a downward angle with needle nose plyers and it made putting it back on quite easy.
7: I do not have a patch panel yet so, I cut three sides of the access panel and then just "scored" the 4th side (drivers side) so I could open it up like a door. It is currently closed and duct tape in on the edges until I can get a proper cover for it.
8: Also, if you read Steve83's writeup, he mentioned that the edges are sharp. let me clairify.
YOU WILL GET CUT!!!!!!! Either wear gloves or file down the edges BEFORE screwing with the pump itself.
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Installation & Overview, In-Tank
Source: by Steve83 (Steve, That dirty old truck) at
http://www.supermotors.net/clubs/superford/registry/2742/12737
Cut-out Panel Fabrication for Fuel Pump/Level Sender Replacement by Shadofax
http://www.supermotors.net/registry/628/15374
Patch Panel, 48 in. x 16 in. for 80-96 Bronco & F Series; $35.00 as of JAN 2012
Source: by Jeff's Bronco Graveyard
http://broncograveyard.com/bronco/i-34094-rear-bed-patch-panel-48in-x-16in-.html
Jeff's Bronco Graveyard also has the other good stuff you'll need
http://broncograveyard.com/bronco/b-549-fuel-systems-bronco.html
Ford has the Motorcraft PFB4 pump for $262.14
Fuel Pump and Strainer Set (Fuel Pump And Bracket Asy. - W/O Sender - Tank Unit - Gas) $262.14 Select a dealer for prices & availability *
There are alternatives to this part. Please contact your dealer.
&
Fuel Sender (Gas) $186.35
http://www.fordparts.com
search for better prices for same Ford pn
such as @
http://www.amazon.com/Motorcraft-PFB4-Fuel-Hanger-Assembly/dp/B000C5DR2G
$259.00 & this item ships for FREE with Super Saver Shipping
Motorcraft PS22 Fuel Tank Sender by Motorcraft
http://www.amazon.com/Motorcraft-PS22-Fuel-Tank-Sender/dp/B000IYLYL2/ref=pd_sim_auto_1/184-5300270-1767324
3 new from $99.76