Replace Fuel Pump 1996 s10 v6 Vortec

[bigs10Henry]

So my fuel pump went out two starts after a new tank of gas and 186K miles. The first start after the tank took a few turns of the starter, the second just made the starter spin and you could not hear the pump engage. After research i concluded that the best way is to take the bed off the truck, one personal experience with taking tank off and about 10 posts in other places that said it was the way to go. We had two men and a female assistant to keep us from losing our tools, which we are prone to doing. :)

Here is exactly how i went about replacing the pump:
1. Sprayed PB Blaster on bed bolts, 8 in all two to the front on each side and two to the rear on each side, btw a friend bought it for me and it was most awesome after about 10 min.
2. took off bed bolts, loosened brake wiring and took off lights for plate illumination
3. took off screws behind gas door so bed will come off, don't try to take off at clamps, almost impossible. If you miss this step it will result in someone really bruised(that's me) or possibly with hernia cause the hoses don't let go easy.
4. Double check there is not something else attached, just cause mine didn't have it doesn't mean yours won't
5. at least 2 people need to slide the bed back 4 feet or so to get to the pump.
6. Test to make sure pump was getting power, if not check the fuse then make sure that the wiring harness is not jacked up.
7. If the pump gets power it's prolly the pump, so took out old and noticed i had to replace one of the harnesses with a new one that supposedly worked better. The information from the pump mfg. said that the models had a problem with the connector so they send a new one, the colors match so it's not a biggie.
8. Blew off the dirt and rust the best i could and pulled pump out. Held on with c-clip. Once the clips is removed just pry a little with a screwdriver against the plastic and it should pop right up, springs will do this. Careful getting it out, it will have a filter and fuel gauge arm on it(need to rotate and tip).
9. Replace the pump but you might need to use the old gasket. The new one i got was too thick and we could not get the pump down far enough to get the whole clip on. It will still work, it has for me. But at least give the new gasket a try.
10. Turn the key on a couple times and see if you hear the pump turn. If not check your wires again and use a tester to make sure it has power.
11. Once it is working(hope it is) then put everything back, make sure that your spare tire access is still accessible, and your lights are all hooked back up.
12. Check lights and put some fuel octain boost in the tank and run about half out of it and then fill up with premium if possible. This will help eliminate bad gas from screwing this one up. If you are really paranoid that bad gas did this then just empty a lot of gas from the tank and fill up with premium from another location.

[Answer069]

I almost had the problem you mentioned with the new gasket but it turned out all you have to do is just push down really hard. It will feel like the dang thing is gonna break but once ya push hard enough it just pops and seats all the way down far enough to get the C-clip in.

[Rinkrat456]

I like this new member. 1st post is well thought out, presented adequately enough to read and understand, and he offers information rather than asks! He searched for his information instead of asking the same questions already answered in previous posts, and in turn offered a great post for others to read and search later on.

Welcome aboard! Good to hear you got your fuel issues worked out.

[67Truckin]

Welcome aboard and nice write-up. The only thing I might add is that the ground wire at the rear corner of the truck bed must be hooked up before testing the new pump. I learned that the ackward way. :rolleyes:

[Answer069]

lol me too!!!!!!!