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Discussion Starter #1
Please keep in mind that this was all done to a 1992 Bronco

1: 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.
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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that ryobi battery powered grinder is a piece of shit. easily the most useless thing i have ever bought, ever. on the plus side, at least you learned something and thanks for sharing.
 
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