Fuel Pump upgrade 125LPH- 255LPH - Ford Bronco Forum
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post #1 of 76 (permalink) Old 11-18-2007, 08:31 PM Thread Starter
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Fuel Pump upgrade 125LPH- 255LPH

The following Tech Write up was completed on a 96 bronco and maybe off interest to those of you that have done upgrades to your engine such as larger injectors, and for those of you that just want a better quality pump.

My factory pump has been screaming like a cat caught in a blender for almost 2 years now. Not wanting to replace it with an over prices original I bought a WALBRO 255LPH fuel pump, part number GSS340 and the 400-812 install kit. This kit is made for a 5.0 mustang and is good for up to 500HP a little over kill for a stock engine which mine isn't.

The original pump flows at 125LPH, so this is a significant upgrade if I can make it work. I know the factory pump is enclosed in a plastic case, at best this will swap right in and at worst I’ll have to fabricate something to make it work.

With the fuel needle on empty lets begin.

The Kit, I also purchased a pump retainer ring – they are usually rusted past reuse.


If you can get your bronco at a comfortable height to work on


Support the tank so you can safely remove the bolts


Remove the 8 bolts holding the skip plate in place, this hold your tang as well.


Disconnect the connector to the fuel pump




Next disconnect the black vent line, the blue fuel line and the gray return line. You need to use a special fuel line disconnect tool for the blue and gray line.




Loosen the clamp to the filler


Lower the fuel tank and set it down were you can work on it. Even with the needle on empty there was still about 20 liters of fuel in the tank. This is a good time to flush your fuel tank or replace it with a new one. Even though mine looks rough its still sound so I'll just flush it.



There is a tool for this but you can make do with a blunt brass chisel. (use a brass punch and not a steel one as shown to avoid sparks) The ring removes counter clockwise.


With the ring removed you can now pull out the pump


To get at the pump you need to remove these 2 bolts and 1 on top


And here is the old pump removed from its plastic hiding place.


The old on the left compared to the new high flow on the right, notice the differences – it isn’t going to be an easy replacement.


Now faced with the fact the new pump isn’t going to be a direct replacement I need to fabricate a bracket. Here I’m deciding on a length for the bracket and that’s going to be 5 inches x 1 ½”.


Cut out of I/8” flat steel


Sorry I changed the design after realizing the pump outlet wouldn’t align with the sending unit.


I form the bracket around a steel pipe similar in circumference of the fuel pump to hold the pump securely.


Bolt it on and clamp the pump in place




Filter now in place and the wires are connected, it is ready for the tank.


Installed in the tank with the new ring and seal.


Now install the tank and test.

Happy to say the pump can no longer be heard and I’ve noticed I bit more pull during wide-open acceleration up an incline in the road to my house. I’m now ready for larger injectors!

Hope this helps.
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post #2 of 76 (permalink) Old 11-18-2007, 08:37 PM
yes
 
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Looks good...I would have cleaned the tank up while i had it out though...

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post #3 of 76 (permalink) Old 11-18-2007, 08:41 PM Thread Starter
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Looks good...I would have cleaned the tank up while i had it out though...
Thanks I should mention that.
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post #4 of 76 (permalink) Old 11-18-2007, 08:43 PM
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Why bother with the time of unbolting the tank, just grind the bolts off.
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post #5 of 76 (permalink) Old 11-18-2007, 08:49 PM
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granted i had to grind a bolt or two off once... not recommended... but why would you grind them???

whyd you go 255lph??? are you planning a big HP motor in the future??? my factory fuel pump whines like all hell...its pretty loud

cost for all of this???

dc

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I want to convert my 4wd Superduty to 2wd. I can take apart a flashlight in under a minute. So im sure i can handle this
check out the broncos full rebuild
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post #6 of 76 (permalink) Old 11-18-2007, 08:51 PM Thread Starter
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Originally Posted by Need4racin View Post


Why bother with the time of unbolting the tank, just grind the bolts off.
Cause mine came right out?
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post #7 of 76 (permalink) Old 11-18-2007, 08:55 PM Thread Starter
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Quote:
Originally Posted by DcSkater602 View Post
granted i had to grind a bolt or two off once... not recommended... but why would you grind them???

whyd you go 255lph??? are you planning a big HP motor in the future??? my factory fuel pump whines like all hell...its pretty loud

cost for all of this???

dc
Price was good - $80.00 off of ebay, and I am building a bigger badder motor and I want to make sure it gets it fuel. And since I had to replace the pump anyways and I don't like doing things twice I went with the better fuel pump now.
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post #8 of 76 (permalink) Old 11-19-2007, 05:55 AM
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Just curious, is the power draw from that 255lph pump significantly higher then the stock pump?

92 EB - 302/E4OD (205,000mi) - Eric
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post #9 of 76 (permalink) Old 11-19-2007, 07:28 AM Thread Starter
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Originally Posted by Bronco4Life View Post
Just curious, is the power draw from that 255lph pump significantly higher then the stock pump?
Certainly there is more draw, our wiring and dedicated fuel pump relay on the bronco are up to the job.
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post #10 of 76 (permalink) Old 11-19-2007, 07:43 AM
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You want to hear something weird? The fuel pump went out on my '95 BMW K1100RS motorcycle, and I couldn't afford the $375 the BMW dealer wanted for it. I ended up using a new Bosch pump for a Ford Explorer 5.0 that looked identical to that, $55 from Advance. Can't speak for the flow numbers, but they look identical. Apparently that style pump really gets around. Nice write up, I love seeing alternatives to the stock stuff.
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post #11 of 76 (permalink) Old 11-19-2007, 09:00 AM
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Quote:
Originally Posted by bossind View Post
There is a tool for this but you can make do with a blunt chisel. The ring removes counter clockwise.

Please people don't use steel/iron/etc for this. You have a fuel tank here that will blow up if you throw sparks.

Get yourself a brass chisel/punch that will not throw sparks.

Think about the poor people that will need to clean up your charred guts!
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post #12 of 76 (permalink) Old 11-19-2007, 09:14 AM Thread Starter
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Quote:
Originally Posted by Seijirou View Post
Please people don't use steel/iron/etc for this. You have a fuel tank here that will blow up if you throw sparks.

Get yourself a brass chisel/punch that will not throw sparks.

Think about the poor people that will need to clean up your charred guts!
Its unlikly but it could happen. I didn't use the punch the ring was too rusty so I pulled it out. I'll update.
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post #13 of 76 (permalink) Old 11-19-2007, 09:17 AM
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Quote:
Originally Posted by bossind View Post
Its unlikly but it could happen. I didn't use the punch the ring was too rusty so I pulled it out. I'll update.

It is unlikely but it only takes one.
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post #14 of 76 (permalink) Old 11-19-2007, 09:20 AM Thread Starter
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Quote:
Originally Posted by Seijirou View Post
It is unlikely but it only takes one.
You point is valid, Iím not arguing with you. I have made the necessary changes to the write up.
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post #15 of 76 (permalink) Old 11-19-2007, 09:27 AM
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Quote:
Originally Posted by bossind View Post
You point is valid, Iím not arguing with you. I have made the necessary changes to the write up.
Sorry I didn't mean to sound argumentative. I'm agreeing with you that it's unlikely. I think we're both in agreement all around.
I saw the change
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post #16 of 76 (permalink) Old 11-19-2007, 01:14 PM
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Heres another write up, thanks to 94Bronc351 for finding it
http://www.nloc.net/vbforum/gen-1-li...-thread-2.html
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post #17 of 76 (permalink) Old 11-19-2007, 01:34 PM Thread Starter
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Originally Posted by beckyandrich View Post
Heres another write up, thanks to 94Bronc351 for finding it
http://www.nloc.net/vbforum/gen-1-li...-thread-2.html
I seen that, but its different than what our Broncos use for a pump housing.
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post #18 of 76 (permalink) Old 11-25-2007, 04:27 PM
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what braqnd was it??? im looking at them on ebay now

dc

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I want to convert my 4wd Superduty to 2wd. I can take apart a flashlight in under a minute. So im sure i can handle this
check out the broncos full rebuild
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post #19 of 76 (permalink) Old 11-25-2007, 06:43 PM
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When I did mine, I cut the black connector off the top of the new pump and I was able to retain the factory plastic bowl thing. That way I did not have to cut/bend up new steel and all that. not saying it is bad just different, and maybe easier.

dcskater602- I used a holly 190lph from a mustang gt. part number 12-901.
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post #20 of 76 (permalink) Old 11-25-2007, 06:46 PM
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Quote:
Originally Posted by bossind View Post
I seen that, but its different than what our Broncos use for a pump housing.
seemed the same to me, I followed that step by step.
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