🔧 Durango - Fuel Pump Module Replacement

On your Durango, the fuel pump is part of an in-tank fuel pump module (it also includes the fuel level sensor). The job is mostly about safely lowering the fuel tank, swapping the module and seal, then re-priming the system and checking for leaks.

Difficulty Level: Advanced | Estimated Time: 3-5 hours

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⚠️ Safety & Precautions

• ⚠️ Work outside or in a very well-ventilated area—fuel vapors are extremely flammable.
• ⚠️ No smoking, sparks, heat guns, or incandescent drop lights near the vehicle.
• ⚠️ Relieve fuel pressure before opening any fuel line to prevent fuel spray.
• ⚠️ Disconnect the negative battery cable to prevent accidental sparks.
• ⚠️ Support the fuel tank with a jack before removing straps—an un-supported tank can drop suddenly.
• ⚠️ Keep a class B fire extinguisher nearby.

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🔧 Required Tools

You'll need the following tools for this repair:

• Safety glasses
• Nitrile gloves
• Fire extinguisher class B
• Floor jack (rated 3-ton minimum)
• Jack stands (rated 3-ton minimum)
• Wheel chocks
• Socket set (8mm, 10mm, 13mm, 15mm) with ratchet
• Extensions (3" and 6")
• Torque wrench (20–200 Nm range)
• Flat trim tool
• Fuel line disconnect tool set (3/8" and 5/16")
• Hose clamp pliers
• Brass punch and small hammer
• Fuel pump lock ring tool (specialty)
• Drain pan
• Shop towels
• Permanent marker

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Fuel pump module assembly - Qty: 1
• Fuel pump module tank seal/O-ring - Qty: 1
• Fuel tank strap bolts - Qty: 2 (recommended if rusty)

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📋 Before You Begin

• Park on level ground, set the parking brake, and chock the front wheels.
• Drive until the tank is as low as possible—less fuel makes the tank much lighter.
• Open the fuel door and loosen the gas cap to release tank vapor pressure.
• Plan your workspace: have a clean table ready for the new module and seal.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Relieve fuel pressure

• Open the hood and remove the fuel pump relay/fuse from the under-hood fuse box (use your owner’s manual cover diagram).
• Start the engine and let it run until it stalls. Crank 2–3 more seconds to release leftover pressure.
• Turn the key OFF.

Step 2: Disconnect the battery

• Use a 10mm socket to disconnect the negative battery terminal and isolate it so it can’t spring back.

Step 3: Raise and support the rear

• Lift the rear with a floor jack (rated 3-ton minimum) at the proper jack point.
• Set the vehicle down on jack stands (rated 3-ton minimum).

Step 4: Support the fuel tank

• Position the floor jack (rated 3-ton minimum) under the fuel tank with a flat piece of wood on the jack pad to spread the load.
• Jack up lightly until the tank is supported (not lifting the vehicle).

Step 5: Disconnect filler neck and vent connections (as needed)

• Use hose clamp pliers to loosen the filler/vent hose clamps you can access.
• Twist hoses gently to break them free—don’t pry hard on plastic nipples.
• Tip: Mark hose positions with a marker.

Step 6: Remove the tank straps

• Use a 15mm socket and ratchet with extensions to remove the fuel tank strap bolts.
• Lower the straps and keep the tank supported by the jack.
• During reassembly: Torque tank strap bolts to 68 Nm (50 ft-lbs).

Step 7: Lower the tank slightly and disconnect lines/connectors

• Lower the jack just enough to access the top/front of the tank.
• Disconnect the fuel pump electrical connector using a flat trim tool to release the lock tab (don’t break the clip).
• Disconnect fuel lines using the fuel line disconnect tool set (3/8" and 5/16"). A disconnect tool slides into the fitting to release the internal spring clip.
• Use a drain pan and shop towels to catch small fuel spills.

Step 8: Lower and remove the fuel tank

• With all lines/hoses unplugged, slowly lower the tank fully using the floor jack.
• Slide the tank out from under the vehicle.

Step 9: Clean the pump area before opening the tank

• Wipe dirt away from the top of the module and lock ring using shop towels.
• Tip: Dirt in the tank can ruin the new pump.

Step 10: Remove the lock ring and fuel pump module

• Use a fuel pump lock ring tool (specialty) to turn the lock ring counterclockwise and remove it.
• If you don’t have the tool: use a brass punch and small hammer carefully on the ring tabs (brass helps reduce spark risk).
• Lift the module straight up and angle it as needed to clear the float arm (fuel level arm).
• Remove the old seal/O-ring from the tank opening.

Step 11: Install the new seal and module

• Install the new fuel pump module tank seal/O-ring into the tank groove (make sure it lays flat and isn’t twisted).
• Carefully lower the new module into the tank, watching the float arm so it doesn’t bend.
• Install the lock ring and tighten using the fuel pump lock ring tool (specialty).
• Torque lock ring to 55 Nm (41 ft-lbs).

Step 12: Reinstall the tank

• Place the tank on the floor jack and raise it partway.
• Reconnect the electrical connector and fuel lines (push until you feel/hear a solid click).
• Reconnect filler/vent hoses using hose clamp pliers and ensure clamps are fully seated.
• Raise the tank fully and reinstall straps using the 15mm socket.
• Torque tank strap bolts to 68 Nm (50 ft-lbs).

Step 13: Reconnect battery and prime the system

• Reconnect the negative battery cable using a 10mm socket.
• Turn key to ON (engine OFF) for 3 seconds, then OFF for 10 seconds—repeat 3 times to prime the system.
• Start the engine.

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✅ After Repair

• With the engine running, inspect under the vehicle for leaks at the fuel line connections and tank seal area.
• Shut the engine off and re-check for fuel smell or wet spots.
• Test drive 10–15 minutes, then re-check for leaks again.
• If the fuel gauge reads incorrectly, re-check the module seating and connector engagement.

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💰 DIY vs Shop Cost

Shop Cost: $900-$1,600 (parts + labor)

DIY Cost: $250-$650 (parts only)

You Save: $650-$950 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 3-5 hours.

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🎯 Ready to get started?

HowToo makes it easy: same-day/2-day shipping on every part, plus all the tools and specialty tools you need! Check out the parts and tools sections below to add everything to your cart.