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Alright after reading your post I sucked it up and cut a hole in bed. I only got half the hole cut today but I can clearly see the 2 hoses deteriorated and almost collapsed going from sending unit to frame lines. I picked up some 3/8 a1-15 line from west marine few weeks ago looks like I will be making a trip there tomorrow for some 5/16. The plan is tomorrow finishing the hole in the bed and hopefully pulling the unit out for inspection. Thank again for giving me motivation to check the sending unit, if the lines on top are in condition they are in then I’m sure there is something going on inside.
 

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Sounds pretty extreme. Most of us would siphon the fuel out and drop the tank, or with the case of no toolbox or 5er hitch, lift the bed.
 

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Well unfortunately about a year ago I installed a 12’ utility body and where the truck is currently I don’t have a way to lift the bed. I figure that I will be easier weld the diamond plate back in and of course Trying to get truck home the other day I just filled tank halfway.
 

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Since the hole is already started I suggest you not weld it back together. Fabricating a hinged door or a removable plate should be a cinch for a guy with welding skills. Dropping a tank with only a little fuel in it is a PITA.
 

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i Was thinking about making a door or something removable Incase in future I would have easy access as I plan on keeping this truck forever. I have pictures somewhere of it brand new in 1994 when my dad purchased it and when he passed about 10 years ago I inherited it and slowly been trying to restore it. I appreciate your help and will post back later with the findings.
 

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Yesterday I did get the sending unit out. The unit is carters with plastic fittings on top. The screen was dirty and metal parts were starting to rust. I’m wondering What the sliding function if the Module is for? And could the rust have caused it to stick up and not let it drop to the lower fuel levels? Anyway I washed everything, the nylon pickup line did not look to have a leak when applying some compressed air. I’m thinking the 3/8 rubber hose with the inner lining coming apart when I took it off may have played a big part in my issue.
 

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The sliding function is for the different sized tanks it is used in. Some variation of that module was used in pickups, SUVs and cars.
 

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That makes sense! Hmm the inside lines don’t appear to have a hole. Do you know what I could use to replace those lines? Joe g write up covered a lot but not much on the inner Module lines.
 

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How did all this end D?

No solution yet, I haven’t been under the hood in a long time. Busy with work, and rodeos this summer. Should be home this weekend, first time since beginning of June. Hope to get the pump pulled and sent off. See what the pros say
 

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Discussion Starter #70
Got the pump rebuilt. Rack #6 plunger where stuck.
Running strong and smooth now though👍. I think the symptoms I was having was that number six plunger Starting to stick.
 
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