Basically, yes. Is there a way to install an intake pump without cutting the bottom of the bucket? This might help fuel stay in the bucket to keep the pump cool. When I installed the 255 I cut the bottom of the bucket to put the filter though.

I might get a Walbro 400, I ha pretty much maxed the 255.

 

I know on my 04, i can let the level drop until the light comes on with no issues, then again i did not cut the bucket.

I believe you can swap out your tank for a new returnless style, that uses the bigger bucket....

 

Swap the entire tank or just the bucket/module?

 

Swap the whole tank. The hole in the top is a different size. I have made a couple threads about this with pics.

 

Took apart the regulator this morning and didn't see any obvious problems.

The fuel pump is still priming, it sounds pretty close to normal, but not quite.

I ordered a Walbro 400, a new bucket module, and a new submersible hose. Also have a hot wire kit that has been sitting around that I'll finally be able to install.

 

Well, turns out the hose burst. Yes, the $20/ft submersible hose. It burst where it was connected to the module, not the pump. Looks like the worm gear hose clamp may have played a part. The hose was also very mushy. It was installed about 22 months and around 10k miles ago. It's only seen 91 octane, no methanol.

I dropped in a Walbro 400 with a proper plastic corrugated hose and Oetiker clamps this time.