Super Duty Fuel Pickup Cleaning

Steve Frazier

Founder
Staff member
From 1999 to about 2007 or so Super Duty chassis cabs were plagued with delaminating fuel tanks. The galvanizing inside would flake off and clog the fuel pickup assembly, and then rust would attack the tank from inside adding to the problem. Eventually the pickup will become so clogged the truck won't run, especially in cold weather when the fuel is thicker. What will follow is a how to on disassembling and cleaning the assembly, saving the cost of replacement or getting back on the road when parts aren't immediately available.

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This is the fuel blender we will be disassembling. First loosen the hose clamp on the black fuel pickup shoe at the end of the assembly and slide off. There is a primary screen that can be removed from this shoe by prying with a small screwdriver so it may be cleaned. Next gently twist and tug the U shaped hose from the stainless tube, do not attempt to remove it from the plastic housing. Now you may gently twist and tug the white plastic assembly from the fuel pickup tube. Set the tubing and fuel guage sender in a safe place.


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Note the two plastic tabs at the bottom of the housing. There is a third tab on the opposite side. To disassemble insert 3 small blade screwdrivers in the gap on the bottom of the assemble directly below the tabs and simultaneously pry lightly so they may slide past the formed clips. Be very careful you don't pry too hard and break the molded clips, use just enough force so they will clear and pull the bottom out of the assembly.


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Here is what you will have. The micro screens simply lift off. Carefully remove the O-ring.


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This amount of debris is minor compared to the first time I did this job. Note the brass plunger and keep it in mind for the next step. It can take off on you if you aren't careful!


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In the slot the O-ring occupied, use a screwdriver and gently twist. You will hear some snapping noises, this is OK. In the next photo you'll see what is happening. When you hear the snap noise, reposition the screwdriver by 90° and twist again until you hear a similar snap, then reposition 90° etc. Repeat until the assembly comes apart. Don't rush this or you can break the retaining pins and it will be junk.
 

Steve Frazier

Founder
Staff member
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This is the assembly split apart after the above step. Notice the 4 small pins that insert to the holes in the other half. These are a very tight fit but will come apart, the snapping noise you hear is the plastic slipping against itself. Just work very slowly and evenly around the assembly and you shouldn't have any trouble. The plastic plunger is on a spring and follower and comes out when the assembly is opened. Just watch for it so it doesn't disappear on you!


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Inside the upper half of the assemble there is a small O-ring that can be removed to facilitate cleaning. Wash all parts in hot soapy water and dry. After washing I still had debris caught in the micro screens, I simply ran a fingernail back and forth over the outside of the screen and this dislodged it. I wouldn't recommend a metal blade of any type, this is very thin plastic that will tear easily.

Reassembly is the reverse of tear down, just don't forget to install the brass plunger assembly. When assembling the two halves of that housing I used water pump pliers expanded to be square to the unit and slowly and evenly squeezed it back together. You'll get the same snapping sound, when it doesn't snap anymore it's tight. Reinstall the large O-ring.Remember to reinsert the small O-ring in the upper half of the housing and install micro screens before inserting the lower half. Just push the halves together and verify the tabs are engaged to the molded clips.
 

Steve Frazier

Founder
Staff member
This was a big issue for chassis cabs that Ford did not take claim for. The typical explanation was "bad fuel" caused the delamination and you are on your own. Replacement tanks were known to have the same issue and were $1000+. I've since found a plastic replacement tank and am installing it, hopefully I won't have any further fuel problems!
 
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