Fuel Pump Replacement in Generation III

[sburtchin]

I'm looking for a thread that tells how to cut an access hole on the Generation III SHO. I found it a year or two ago. Now I can't find it. I thought it was on this forum. It had something to do with the Phoenix Project I think. In the one I'm looking for, he cut a nasty looking hole with power shears and patched it up with aluminum sheet (or cardboard?) and duct tape.

Please help! My 1999 Taurus is dead in the driveway. Thanks!

 

[stephen newberg]

Maybe it was in V8SHO.com. But I admit to not being fond of the idea of cutting a hole in the car wand patching it with "aluminum sheet (or cardboard?) and duct tape". That sounds like a really bad idea.

pax, smn

 

[sburtchin]

Thanks for the tip. I'll check there too.

and patching it with "aluminum sheet (or cardboard?) and duct tape". That sounds like a really bad idea.

I'm with you there. I can just imagine several gallons of gas spraying through that hole into the cabin. My plans are to weld a ****** onto the cut piece and reattach to the body with an ample supply of screws and caulk.

I think it was just about a year ago that I ran across that thread entirely by accident and printed it because I thought it might be useful someday. Now the printout has vanished and I have tried Google, Bing and AVG search engines and it is nowhere to be found. If anybody remembers seeing that thread, please post a link. Thanks.

 

[sburtchin]

Not the one I was looking for (still wish I had that one), but I found this at V8SHO.com: Fuel pump cutout
. Really, really tough to follow because the pictures are so small. You have to click on each one and study them.

I need some help with the very last photo. Where is the electrical connector for the fuel pump? I really don't want to have to reach under a cut edge to get to it.

Why is there an angled cut? Why not just cut out a rectangular opening?

 

[sperold]

I have found that by the time you avoid taking the tank out..... you could have taken the tank out. Up here, in the land of ice and snow and salt, the tank springs a leak long before the pump gives up.... usually at the seam where the two halves are put together.
I was surprised at how well the whole job went. If you do insist on cutting an access hole, it is a lot easier with the tank removed, and you could even weld-in a little door bolting mechanism for the future. That would be a good idea if you worry about the new pump having the infant mortality thing.

 

[Mr Anonymous]

Yup, just take the tank out. If that's too difficult, you may want to consider hiring someone else to do the work.