How to Change a Fuel Pump in a Dodge Ramby Chris Moore
The Dodge Ram's fuel pump is contained within a module inside the fuel tank; to replace the pump module, you must remove the fuel tank from the truck. While individual components in the module, like the fuel level sending unit, can be changed out, it is much easier to replace the module as a whole.
Removing the Fuel Tank
Relieve the pressure in the fuel system--remove the filler cap to relieve pressure in the tank, then remove the fuel pump relay in the fuse box. Crank the engine for several seconds and look for it to stall after running for a few seconds or not start at all. Disconnect the negative battery cable.
Raise the rear end of the truck and support it on jack stands. If you have a four-door Ram with a six-foot bed, remove the left rear wheel.
Disconnect the hoses from the metal pipes on the fuel and EVAP lines by loosening their clamps with a flat-blade screwdriver.
Support the tank by raising a transmission jack or floor jack underneath it. If you use a floor jack, place a block of wood on the jack head to protect the tank.
Unstrap the tank from the vehicle by removing the nuts on the straps with a wrench. Lower the jack until the tank is low enough for you to disconnect the electrical connector and the fuel supply line from the fuel pump module. Disconnect these and remove the tank.
Changing the Pump Unit
Clean the surface of the fuel tank with acetone or lacquer thinner, especially around the pump module, to prevent contaminants from entering the tank.
Disconnect the fuel line from the fuel filter and pressure regulator by depressing the quick-connect fitting tabs. Unplug the electrical connector by pushing the lock toward the fuel line fitting and depressing the release button.
Turn the lock ring on the fuel pump module with a large pair of pliers. You can also tap on the lock ring with a hammer and drift, turning it clockwise. Unscrew the ring once it is loose.
Lift the fuel pump module carefully out of the tank. Check the condition of the rubber gasket on the mounting hole and replace it if it is cracked, torn or damaged in any way.
Install the new fuel pump module within the tank, rotating it so the alignment arrow on the module lines up with the middle of the three hash marks on the top of the tank. (The fuel pipe on the filter/pressure regulator must also point toward the driver's side of the truck.)
Re-attach the lock ring on the module, using the pliers or the hammer and drift to tighten it.
Re-connect the fuel tank onto the truck and connect all the lines to the tank in the reverse order of removal. Replace the wheel if you removed it, and lower the truck once the tank is secure.
Connect the negative battery cable and the fuel pump relay. Turn the ignition switch to the "On" position for two seconds. Turn it back off for five seconds. Repeat several times. (This will re-pressurize the fuel system.)
- Wait until there is as little fuel in the tank as possible before changing the filter.
Items you will need
- Jack stands
- Lug wrench
- Flat blade screwdriver
- Acetone/lacquer thinner
- Large pliers
- Hammer and drift (optional)
- Fuel pump module
- "Dodge Pick-ups: 2002 through 2005 (Chilton's Total Car Care Repair Manual)"; John Wegmann; 2006
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