Dodge Ram 2002-2008: How to Replace Fuel Pump

Is your fuel pump causing you problems? Although replacing it will get you dirty, the process is easy to do. Here is how to replace the fuel pump on your Dodge Ram.

By Neftali Medina - July 17, 2015
Contributors: AirTex Pumps, Dakota-Durango

This article applies to the Dodge Ram (2002-2008).

A fuel pump does what its name entails: it pumps fuel. You can actually hear a fuel pump prime when you start your vehicle. If you listen carefully, a healthy pump will make a quiet whirring noise just before the engine ignites. When a pump fails, the truck will not run. In this situation you have two options: either pay several hundred dollars to have a shop replace it for you, or spend under $200 and complete the repair yourself. In order to replace it, you will have to remove the tank from your truck, clean it out, and install a new pump. Although there is a bit of heavy lifting involved, the process is fairly simple to complete. Use the following instructions to replace the fuel pump on your Dodge Ram.

Materials Needed

Jack
Jack stands
Punch and hammer
Meter
Screwdriver
Socket set
Gas tank
Soap and water

Step 1 – Disconnect the negative battery cable

Disconnect the negative battery cable to avoid accidental shock.

Figure 1. Disconnect the negative battery cable.

Step 2 – Release the fuel pressure

Hook up a line to the fuel pressure regulator and release the pressure from the system. Be sure to direct the leaking fuel into a gas can.

Step 3 – Raise the secure your truck

Use a jack at the correct jack point of the Ram.
Raise it and place jack stands underneath to support the chassis (either the axles or the frame).

(Related Article: How to Jack Up Your Truck - Dodgeforum.com)

Step 4 – Disconnect the fuel filler line

Use a screwdriver to undo the fitting and disconnect the fuel filler line.

Figure 4. Disconnect the fuel return line.

Step 5 – Support the gas tank and remove it

Place another jack stand underneath the gas tank.
Remove each of the strap bolts from underneath the chassis.

Figure 5. Remove each strap bolt from the tank.

Disconnect the fuel line from its supporting clip.
Remove the vent line to the pump assembly.

Figure 6. Remove the fuel line from its support clip on the chassis.
Figure 7. Remove the vent line.

Unplug the electrical connection to the fuel pump.
Remove the fuel line from the fuel pump.
Drop the fuel tank.

Figure 8. Remove the fuel line.
Figure 9. Drop the fuel tank.

Step 6 – Clean the tank and remove the old pump

Clean the tank using soap and water.

Use a hammer and punch to open the tank ring. Do not bend or damage the ring during its removal process.
Pull out the pump assembly.

Figure 11. Use a punch to release the tank ring.
Figure 12. Remove the old pump.

Step 7 – Install the new fuel pump

Before installing the fuel pump, use soap and water to clean out the old tank. Make sure to rinse and repeat until all the old build up is removed from the tank.