I run a FASS 150/150 lift pump. I had issues with the FASS cavitating and pulling air when the tank were to go below a third of a tank. I bought a fuel sump from Joe Hellmann at [url=http://www.hellmannperformance.com[/url]. It has been one of the best mods I have done and I really think it will help the longivity of my FASS pump. This mod also cures trying to upgrade to bigger pickups for more fuel. This fuel sump will work on any car/truck, all you need is 5 inch flat surface.
1. No more pick-up tube in the tank!
2. I have run my tank near empty without the FASS pulling any air.
3. My FASS has quieted down where you can barely tell it is running!! I used to be able to hear it in the cab, now I can stand next to the truck when its running and not hear the pump.
4. I also have started putting 40-50 extra miles between fill-ups. Literally you can run your tank dry.
5. My fuel pressure came up an extra pound, from 11 to 12 lbs and never fluctuates like it did before when I got below a third of a tank.
1. It sits below the fuel tank so lowers the ground clearance.
2. Drilling a hole in the bottom of my tank bothered me.
Fuel Tank Removal - Dodge Truck
(1) Loosen clamp and disconnect rubber fuel fill
hose at tank.
(2) Support tank with a hydraulic jack.
(3) Remove 2 fuel tank strap nuts and
remove both tank support straps.
(4) Carefully lower tank a few inches and disconnect
fuel pump module electrical connector
at top of tank. To disconnect electrical connector:
Push upward on red colored tab to unlock. Push on
black colored tab while removing connector.
(5) Disconnect fuel supply and return lines at fuel
(6) Continue to lower tank for removal.
(7) If fuel tank is to be replaced, remove fuel tank
module from tank.
Tank pulled out:
Marked the tank and getting ready to cut the hole:
Cutting the hole for the fuel sump:
Hole cut and cleaning the burs:
Drilling the holes. Drill the first hole and install the bolt. Move around the continuing to drill holes and install bolts. This will insure all the holes are exact for a perfect fitment:
Mounting holes drilled:
Installing my barbed fitting for my fuel line. Use lock-tite to ensure no leaks. This is better than using teflon tape etc.:
Looking thru from the top of the tank:
Cleaned the surface with purple power and used a little sealant along with the supplied seal since the Ford tanks are rigid and do not have a smooth surface:
Installed shot from the inside:
Installed shot from outside:
Capped off the old pickup tube with compression fitting and brass cap:
Fuel Tank Installation - Dodge Truck
(1) Position fuel tank to hydraulic jack.
(2) Raise tank until positioned near body.
(3) Connect fuel tank module electrical connector
at top of tank.
(4) Connect fuel supply and return lines to
(5) Continue raising tank until positioned snug
(6) Install and position both tank support straps.
Install 2 fuel tank strap nuts and tighten. Tighten
rear strap nut first. Torque to 30 ft/lbs.
(7) Remove hydraulic jack.
(8) Connect rubber fill hose to fuel fill tube
(9) Install tire / wheel (if necessary).
(10) Lower vehicle.
(11) Fill fuel tank with fuel.
(12) Start engine and check for fuel leaks near