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8.1L fuel pump replace with tilt bed method

8.1L fuel pump replace with tilt bed method

Postby sam1340 [OP] » Mar 10 2019, 2:16am

I have a 2002 2500HD 8.1L w/Allison trans. I have 16 psi fuel pressure after fuel filter change, truck dies when given throttle. 181k miles on original pump. Looking to do the bed tilt method to replace pump. My question is ... the truck bed has a fiberglass ARE cap on it. I see where I need to remove the tailgate from a youtube video but can't find any mention of anyone ever removing a cap prior to tilting bed. Do I need to take the cap off ? Not sure if it will flex when tilting bed, don't want to crack it. Trying to get everything in a row prior to this repair. Thanks
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Re: 8.1L fuel pump replace with tilt bed method

Postby gphipps33 » Mar 10 2019, 7:13pm

If nothing else it will make the bed lighter and easier to lift.
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Re: 8.1L fuel pump replace with tilt bed method

Postby 19trax95 » Mar 10 2019, 7:15pm

You shouldn't need to take it off. Unless it is really close to the cab, then it could hit I suppose.

I'd probably try to leave it on. Makes it faster and easier. They aren't that heavy, and the bed isn't too bad either. Especially since your only tilting one side of it.
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Re: 8.1L fuel pump replace with tilt bed method

Postby sam1340 [OP] » Mar 12 2019, 11:45pm

I found this video of a guy tilting the bed with the tailgate and cap in place. Looks like it's a go to leave the cap in place. That's gonna save me a bunch of time and energy.

https://youtu.be/-GbZlNO7ruc
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Re: 8.1L fuel pump replace with tilt bed method

Postby sam1340 [OP] » Mar 19 2019, 12:01am

Success ! Took me about 5hrs but did it all myself. Left the bed on, removed tailgate. Cardboard between bed and cab to protect finish. Used two floor jacks and two 28" 4x4's to jack the bed up. put two jack stands between bed and chassis and a stack of boards just for insurance. Pump came right out. The hardest part was getting the lock ring to reseal with the new pump. I could never get it tight enough so that when I hit it with the brass drift it would lock, it kept popping free. I used a 12" set of ChannelLocks and was able to tighten the ring enough so I could seal it up with the brass drift. Rewired the harness, the colors were a perfect match. Bolted it all back up and it's good to go. I hope this Delphi pump lasts awhile, not eager to do this again.
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