SOURCE: Ford F100 Fuel System
There are a couple things here. In the first place if you can pump fuel with the pump off the engine and pumped by hand doesn't mean that it will pump on the engine. See the stroke on the engine is very short, it only moves like 1/4 inch. So you could have a bad pump even though you are pumping by hand. The gas cap, will have no effect on this model. Yes the pick-up tube has a filter on the bottom of it, and it could be stopped up. You can remove this unit up through the top of the tank, got to wiggle it and turn it sideways, and if you can find a used one( New ones scarce and expensive) by going to used parts place, and look for 1967 - 1972, they are all alike. Lots a luck in fixing this great ole truck.
SOURCE: 1995 Ford Bronco 172 EGO not switching lean bank1- jerks when run
Have u checked for vacuum leaks or poss leaking EGR valve? use carb spray around the upper intake manifold where it bolts to the lower manifold, spray vacuum lines where they are connected to the engine vacuum ports, the idle speed will change if u hit a leak, as far as the EGR valve goes see if it gets hot at idle, if it does it is leaking, if all checks ok replace the O2 sensor, but i suspect u will find a leak at the upper intake plenum.
SOURCE: check engine light
this is very common on these. the upper intake seals leak and should be replaced. It is not a noticable vacuum leak and is usually worse when the engine is cold. It is not a very difficult job to do
SOURCE: pushing fuel out the filler neck
Was the fuel check valve recall performed on this truck? These are similar symptoms to the recall in which gas would pump from one tank to another.
SOURCE: Replacing fuel filler neck on 2000 Crown Vic
Good news, no the tank doesn't have to come down. However, there needs to be less than 3/4 tank. Jack it up and set on a jack stand, remove the wheel, four screws housing to pipe, filler pipe sensing hose from filler pipe, screw retaining the cap, four retaining screws from filler pipe, screw from filler pipe retainer, slide into the tank until it can be rotated and pulled out through the fender. lube the tank grommet with clean oil and reverse the removal for install.
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