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114 Posts
Discussion Starter #1
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 . 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
tank module.
(6) Continue to lower tank for removal.
(7) If fuel tank is to be replaced, remove fuel tank
module from tank.

Tank pulled out:

Old configuration:

Marked the tank and getting ready to cut the hole:

Cutting the hole for the fuel sump:

Hole cut and cleaning the burs:

Test fit:

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
tighten clamp.
(9) Install tire / wheel (if necessary).
(10) Lower vehicle.
(11) Fill fuel tank with fuel.
(12) Start engine and check for fuel leaks near
of module.

358 Posts
I like this idea and wonder why someone hasn't done this sooner. this should correct any 1/4 tank right? Would sediment get in the fuel lines now? Just a couple of thoughts.

114 Posts
Discussion Starter #5
I really don't have a definite answer on whether its legal, I would check you states safety inspection laws. Texas says nothing so I am sure its fine.

It corrected the 1/4 tank issue for me and then some.

As far as the sediment goes, my tank is 11 years old and was very clean. With a good filter I don't see you having any problems. I have always tried to fill up at large truck stops or newer stores so they will have fresher and cleaner fuel. You could also run a cheap in-line filter and replace it every oil change just to have piece of mind.

Its a really nice aluminum piece. Mine still has the tooling/machining marks, but thats the way I wanted it, but I am sure you can get it polished too. I am one of those people who never grind down the welds because I like to show off the fab work.

You can run just about any size fuel line from 1/4" to 1", I am running a 1/2" feed line to the pump then from the pump 3/8" to the engine till I get my go fast parts then I will upgrade to 1/2" all the way.
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