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Unread 01-24-2010, 12:38 AM   #1
The_Aaron
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1998 TJ Wrangler 
 
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strange method of replacing fuel pump

So, my fuel pump went on my 4-banger earlier this week, and I've been having alot of trouble getting the tank down. I have a good 7-8 gallons in there, all the bolts are rusted on (even though i gave them a good spraydown with PB blaster), my neighbor's floor jack broke, and i'm running out of ideas here.
My friend told me that everytime he's replaced a fuel pump in a car, he cuts a hole in the floor above the tank, pulls the pump out, puts a new one in, and bolts a slightly larger piece of metal over it. That way if anything goes again, it's all accessable. The idea to me sounds pretty out there, but he's very well respected as a mechanic locally. Does this seem like something worth trying?
The reason i'm really considering this is because i was hospitalized yesterday with 7 kidney stones and a kidney infection (and i'm only 19) , and i have to take it easy with exerting myself for a few weeks, but i still need my jeep to get to work.

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2.5L went kaboom september 2010 with 160k
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Unread 01-24-2010, 12:50 AM   #2
dmgiff
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On the surface, I really like the sound of this idea. I just did my fuel pump about four weeks ago and I never thought of doing it this way. First questions that come to mind are what would you use to cut it? How would you ensure the location is directly above the fuel pump? The floor isn't flat, so it might take some skilled sheetmetal work to bolt something back in place.
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Unread 01-24-2010, 01:02 AM   #3
The_Aaron
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i know the fuel pump is in the center of the tank, so i think measuring the width and length of the tank and centering that in the tub should put me exactly where i need to be. my friend said he did his with a grinder, because that was the best way not to punture the tank. the sheetmetal part i'm a bit sketchy about, but i'm not entirely concerned about the look as long as it's sealed, because it will be under the backseat.
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2.5L went kaboom september 2010 with 160k
currently in the works: '97 TJ 4.0/'96 XJ ax-15/'99 XJ np231/'01 TJ dana 44 swap
I have a low post count because I spend more time wrenching than I do talking about it.
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Unread 01-24-2010, 01:14 AM   #4
jurob
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i've seen some imports that have access to the fuelpump that way from the factory. if your too lazy to drop the tank or don't feel comfortable i don't see any reason not to do it that way.
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Unread 01-24-2010, 01:19 AM   #5
jurob
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reread your post, i say go for it.
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Unread 01-24-2010, 01:21 AM   #6
ArrizX
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As long as you keep it covered with the seat and the carpet no one would ever know. Sounds easy!!
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Unread 01-24-2010, 01:22 AM   #7
ArrizX
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For the record, use a die grinder. You know, the high speed air cut off wheel. That use like the 3''disks that spin at like 10k
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Unread 01-24-2010, 02:23 AM   #8
KKiowaTJ
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IMO Id do it right and put new tank straps and bolts in. Cutting and hacking on your tub, It already has alot of holes on the floor. I understand sometimes you run into a time you have to do that, But not for a jeep. I have herd of this before and always thought of shade tree hacks cutting up your car and pop rivet down some sheet metal and call it good. Moisture gets in, Starts rust, etc and if you have a nice car, Even worse. To each his own, Good luck
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Unread 01-24-2010, 09:05 AM   #9
marc1kim
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I've worked on cars that have had the trap door in the trunk, don't know why everyone doesn't make this standardized. It sounds like a good idea...I've heard of some people doing this on their pick up trucks.
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Unread 01-24-2010, 09:24 AM   #10
Jason
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Word of caution: Be careful cutting above the gas tank. Make sure you know what is under your cut. Sparks from a cut-off tool or grinder and gasoline don't mix. Sounds like you've had your fill of hospitals lately.
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Unread 01-24-2010, 10:16 AM   #11
reddevils
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it's not quite a strange method,i'v seen it done a bunch.one thing has been in common every time,you wind up with a P.O.S.job every time.but it works.
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Unread 01-24-2010, 10:21 AM   #12
FMJ
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I did that trick on a 92GMC pickup one time. Never did get the sheet metal to fit right. But i only had to drive it for about 6 months until the plates ran out.
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Unread 01-24-2010, 11:34 AM   #13
reddevils
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on a G.M.pickup you spend more time cutting the hole in the bed than you do doing the job the rite way.the rite way on a G.M.pickup is to remove 4 bed bolts unplug light harness and slide the bed back,twenty min.tops,and no hole,no patch to make.
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Unread 01-24-2010, 11:43 AM   #14
Jerry Bransford
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Even with 7-8 gallons of gas in the tank, it's not a big enough deal in my opinion to warrant cutting a hole the floor above the tank simply to avoid dropping the fuel tank.

Ask mrblaine if that much fuel in a gas tank is enough to make dropping the gas tank a big deal. I forgot I was heading over to his house the next day to install my gas tank skid which required the gas tank be dropped & filled the tank up. We dropped it without issue after I got the infamous "Blaine Glare" when I mentioned to him that I had accidentally filled the tank the previous day.
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Unread 01-24-2010, 12:48 PM   #15
MM1Jeeper
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I dropped the tank in my expedition with over half a tank of gas left in it. Thats over 13 or 14 gallons. Wasn't fun, but after it was down pumped it out and it made reinstallation so much easier. I wouldn't cut the hole in the floor and I don't have any qualms cutting up my jeep for things, just not unnecessarily.
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