Here's a general outline of the process. This is not a comprehensive guide and may not cover all variations for your specific truck. Always consult a repair manual specific to your year, model, and engine for detailed instructions and diagrams. A Haynes or Chilton manual is a good investment.
1. Safety First:
* Disconnect the negative battery terminal.
* Release fuel pressure. This is crucial to prevent fuel spray. The method varies depending on your truck's system; you may need to crank the engine until it stops (after disconnecting the fuel pump relay) or use a fuel pressure release tool. Refer to your repair manual.
* Work in a well-ventilated area. Fuel fumes are dangerous.
* Wear safety glasses and gloves.
2. Preparation:
* Gather tools: You'll need various sockets, wrenches, screwdrivers (possibly including Torx bits), a fuel pump removal tool (often a specialized socket), jack stands, jack, and possibly a fuel line disconnect tool.
* Locate the fuel pump access panel: This is usually under the rear seat of the truck. You might need to remove the seat and potentially some interior trim panels to access it.
3. Fuel Pump Access and Removal:
* Remove the access panel: This often involves removing bolts or clips.
* Disconnect the electrical connector: Carefully unplug the fuel pump electrical connector.
* Disconnect the fuel lines: Use a fuel line disconnect tool (highly recommended to avoid damage) to disconnect the fuel lines leading to and from the fuel pump. Have rags ready to absorb any spilled fuel.
* Remove the fuel pump retaining ring: This often requires a special fuel pump retaining ring tool. The ring holds the pump assembly in place.
* Remove the fuel pump assembly: Carefully lift the assembly out of the tank. It might be helpful to use a fuel pump removal tool to help guide it out.
4. Installation of the New Fuel Pump:
* Inspect the fuel tank: Check for any debris or damage inside the tank.
* Install the new fuel pump assembly: Carefully lower the new fuel pump assembly into the tank, ensuring it's properly seated.
* Install the retaining ring: Securely install the retaining ring using the appropriate tool.
* Reconnect the fuel lines: Carefully reconnect the fuel lines, using the disconnect tool to ensure a proper seal.
* Reconnect the electrical connector: Plug the electrical connector securely back onto the fuel pump.
* Reinstall the access panel: Put the access panel back in place and secure it.
5. Re-pressurization and Testing:
* Reconnect the negative battery terminal.
* Prime the fuel system: You may need to cycle the ignition switch (on and off) a few times to prime the fuel pump.
* Check for leaks: Carefully inspect all connections for fuel leaks.
* Start the engine: Listen for any unusual noises and check for any further leaks.
* Test drive the vehicle: Take the vehicle for a test drive to verify proper operation.
Important Considerations:
* Fuel Pump Selection: Make sure you purchase the correct fuel pump for your specific year, make, model, and engine.
* Repair Manual: A repair manual is invaluable for detailed instructions, diagrams, and torque specifications.
* Professional Assistance: If you're uncomfortable performing this repair yourself, it's best to take your truck to a qualified mechanic. Improper repair can result in a dangerous situation.
This is a general overview. Consult a repair manual specific to your 1999 Dodge Ram 1500 for the precise steps and safety precautions. Remember, safety is paramount. If you have any doubts, seek professional help.
