Clunk
New member
- Joined
- Dec 6, 2008
- Messages
- 249
Here's the whole job from 5 years ago,
I have a Carter 4601hp(thanks BIGHEAD) pump installed in front of my fuel tank and mounted on the frame rail. This is how I installed it.
I let the fuel level get down to 1/4 tank, disconnected the battery cables, set the parking brake...you know the drill..drained the fuel filter by opening the water in fuel valve & let it pour into a drain pan then closed the valve.
I removed the old lift pump, removed the fuel line but left the fitting on my filter, then raised the front of the truck and supported it with jack stands high enough so I could work and kinda judged it to be high enough to keep fuel from pouring out of the fuel tank onto me when I cut the fuel supply line.
I lowered the fuel tank to lift pump supply line so fuel could pour into the drain pan and determined the front of the truck was higher than the fuel level in the fuel tank so I could proceed with the job.
After determining a clear place for the new pump and cutting the fuel supply line, I disconnected the front driveshaft at the front differential and tied it up out of the way so I could get a drill in there.
Using the supplied mounting bracket, I located where to drill the holes into the frame rail and drilled them. Because the frame rail is boxed, I used the drill size recommended on the fine thread 5/16 tap (I forget what size), drilled & tapped the holes and installed the bracket. I put some red Loctite on the bolts and just pulled them snug because of the the frame is kinda thin and let the red Loctite take a set and hold the bolt's in place. Following the instructions, I installed the lift pump with fittings on to the bracket, put a short 3/8 fuel hose on the cut fuel supply line to the fitting on the inlet side of the fuel pump. I installed a 3ft. piece of 3/8 fuel hose from the fitting on the outlet side of the pump and connected the other end to the fuel filter fitting.
The original lift pump had a 2 wire plug in electrical connector and the Carter I bought doesn't so I cut the connector off, butt spliced, soldered and double heat shrink (shrunk,shrank?) insulated 2-3ft. pieces of same guage wire. I had to pull the original wires down between the starter and the engine block to have room to work...kinda close around the motor mounts.
After soldering 2 heavy ring connectors (not the 2 little ones supplied with the kit) on the new wrapped and trimmed to fit electrical wires, I connected one to each electrical post on the pump.
After rechecking all the hoses, clamps and wiring and the proximity of same to heat or moving parts and finding everything safe, I reconnected the front driveshaft and let the truck off the jackstands. After checking for leaks and finding none, I disconnected the fuel pressure guage line at one joint and put on an extension hose so I could bleed air & foam off the system into the drain pan before trying to start the engine.
I reconnected the battery cables.
After bumping the starter with the keyswitch, the new lift pump started and ran for around 20 seconds. No fuel came out and the end of the fuel line had a slight vacuum when I put my finger over it so I swapped the electrical connectors on the fuel pump and tried again. This time when I bumped the starter, fuel & air flowed out the line with good pressure. I bumped the starter 3 more 20 second cycles until the fuel coming out had no air showing then reconnected the fuel pressure guage line back to normal. Upon bumping the starter yet again and finding the fuel pressure at 15 psi, I started the motor. After starting, it chuckled a coupla times then idled smooth.
It has worked great since September 2004.
I have a Carter 4601hp(thanks BIGHEAD) pump installed in front of my fuel tank and mounted on the frame rail. This is how I installed it.
I let the fuel level get down to 1/4 tank, disconnected the battery cables, set the parking brake...you know the drill..drained the fuel filter by opening the water in fuel valve & let it pour into a drain pan then closed the valve.
I removed the old lift pump, removed the fuel line but left the fitting on my filter, then raised the front of the truck and supported it with jack stands high enough so I could work and kinda judged it to be high enough to keep fuel from pouring out of the fuel tank onto me when I cut the fuel supply line.
I lowered the fuel tank to lift pump supply line so fuel could pour into the drain pan and determined the front of the truck was higher than the fuel level in the fuel tank so I could proceed with the job.
After determining a clear place for the new pump and cutting the fuel supply line, I disconnected the front driveshaft at the front differential and tied it up out of the way so I could get a drill in there.
Using the supplied mounting bracket, I located where to drill the holes into the frame rail and drilled them. Because the frame rail is boxed, I used the drill size recommended on the fine thread 5/16 tap (I forget what size), drilled & tapped the holes and installed the bracket. I put some red Loctite on the bolts and just pulled them snug because of the the frame is kinda thin and let the red Loctite take a set and hold the bolt's in place. Following the instructions, I installed the lift pump with fittings on to the bracket, put a short 3/8 fuel hose on the cut fuel supply line to the fitting on the inlet side of the fuel pump. I installed a 3ft. piece of 3/8 fuel hose from the fitting on the outlet side of the pump and connected the other end to the fuel filter fitting.
The original lift pump had a 2 wire plug in electrical connector and the Carter I bought doesn't so I cut the connector off, butt spliced, soldered and double heat shrink (shrunk,shrank?) insulated 2-3ft. pieces of same guage wire. I had to pull the original wires down between the starter and the engine block to have room to work...kinda close around the motor mounts.
After soldering 2 heavy ring connectors (not the 2 little ones supplied with the kit) on the new wrapped and trimmed to fit electrical wires, I connected one to each electrical post on the pump.
After rechecking all the hoses, clamps and wiring and the proximity of same to heat or moving parts and finding everything safe, I reconnected the front driveshaft and let the truck off the jackstands. After checking for leaks and finding none, I disconnected the fuel pressure guage line at one joint and put on an extension hose so I could bleed air & foam off the system into the drain pan before trying to start the engine.
I reconnected the battery cables.
After bumping the starter with the keyswitch, the new lift pump started and ran for around 20 seconds. No fuel came out and the end of the fuel line had a slight vacuum when I put my finger over it so I swapped the electrical connectors on the fuel pump and tried again. This time when I bumped the starter, fuel & air flowed out the line with good pressure. I bumped the starter 3 more 20 second cycles until the fuel coming out had no air showing then reconnected the fuel pressure guage line back to normal. Upon bumping the starter yet again and finding the fuel pressure at 15 psi, I started the motor. After starting, it chuckled a coupla times then idled smooth.
It has worked great since September 2004.
