In tank Walbro in a 2002 fuel sender-pics
 

I just finished modifying my fuel sender to accept the walbro intank pump.
First let me say, this is not the best way to upgrade your pump unless you are willing to keep at least 1/4 tank of gas in the tank at all times. Reason being is this eliminates the function of the fuel sender bucket. The stock fuel pump has 2 inlets and feeds from inside the fuel bucket and outside the bucket. Aftermarket pumps do not have 2 inlets. I first had to cut down the inside of the bucket so the Walbro would poke though the hole far enough so the new sock would attatch and it could pull gas from the bottom of the tank.
I stuck a couple of o-rings on the pump inlet in hopes it will seal off good enough so the return line will fill the bucket and keep the pump submerged and cool. The new pump is alot shorter than the stock pump, so I used a ziptie to secure it firmly in place so it cant jump around. The plastic flex fuel line is a major pain to get off the stock pump, just have to keep prying on it with a screw driver and it will eventually come loose, then you will have to use a small hose clamp to secure it to the new pump outlet. Had to splice in the connector that goes with the pump, I soldered the wires and used heat shrink tube afterwards. Got it all back together and cant wait to get it back in the truck. The truck is at work, so tommorrow I will finish it up.
Note-this does not pertain to 2003 and newer fuel senders, those are different.
Not being able to take full advantage of my gas tank capacity doesnt bother me any. I never fill it up anyway, so i guess I will just use 1/4 as empty now.
I do plan to take it out with a 5 gallon can of gas in the bed to see how empty it can go under normal driving before it starts to run out.
http://www.sighost.com/user/ranwalk/dsc03190.jpg
http://www.sighost.com/user/ranwalk/dsc03191.jpg
http://www.sighost.com/user/ranwalk/dsc03192.jpg
http://www.sighost.com/user/ranwalk/dsc03193.jpg
http://www.sighost.com/user/ranwalk/dsc03194.jpg
http://www.sighost.com/user/ranwalk/dsc03196.jpg
http://www.sighost.com/user/ranwalk/dsc03197.jpg
http://www.sighost.com/user/ranwalk/dsc03198.jpg
http://www.sighost.com/user/ranwalk/dsc03199.jpg
http://www.sighost.com/user/ranwalk/dsc03200.jpg
http://www.sighost.com/user/ranwalk/dsc03201.jpg
http://www.sighost.com/user/ranwalk/dsc03202.jpg
http://www.sighost.com/user/ranwalk/dsc03203.jpg

Nicely done. I was hoping to see some pics of that. Now I know what im up against when I do this.

when you find out were it runs out. just move the niddle on you gauge :smokin2:

So what can you do to upgrade your fuel pump if you want to ba able to use the full capacity of the tank?

Only other option I know of is to go with an inline pump. Hopefully, someone
will start making a pump for us 2002 and earlier guys that can be a direct
swap.

Ok, got the tank back in. Had less than 1/8 of a tank of gas in it. turned on the key, waited a sec and the fuel pressure guage jumped on up. Truck started right up, I went ahead and got 5 gallons put in it before I even thought about driving it. Going to go straight to a gas station and fill it up and see how it does. I'll start another thread with test drive results :cheers:

I don't see why you think you need to keep a min of a 1/4 tank, or it will run out, looks like your pickup filter sock is going to set right on the bottom of the tank :confused: I would think it would still pick 97% of the fuel in the tank. I guess my 01 didn't have the 2 pickup, it just sucked out of the bucket.

Edit: just looked at my stock pump and it does have the 2 pickup, but I still think mine will pickup amost all the fuel in the tank. I know it will pickup after the light comes on :)

It will probably be fine less than 1/4, i just remember Parish bringing up the fact that he sucked some air on a hard launch with a little under 1/4 tank with his dual intank setup. I will run it on down one day to see how far it can go before it starts to run out.

looking good
Did you make sure that heat shrink is ok in Gas
I usually test things in a jar of gas before i stick them into a spot like that
Ditto on the sucking up air part .In a stock application i'm sure it would be fine.
When yoiu have 2 pumps and are making over 500rwhp i don't chance it at all ..

I'm rolling the dice on the heat shrink, I didnt test it :(
If it does come off I think i'll be ok, the wires are no where near touching each other, only time will tell now :eyes: Normal driving, I may run it low, but if I know I'm going to be playing it will have to have enough gas in it that I feel confident I wont run out.