Bad Fuel Pump? Here Are the Signs, Replacement Time, and Cost

Have you ever encountered situations where heavy equipment suddenly fails to start, experiences a loss of power during operation, or even behaves sluggishly despite the throttle being fully depressed? Don’t panic—these issues are likely caused by a malfunctioning fuel pump! For heavy machinery such as excavators, loaders, and bulldozers, the fuel pump serves as the “heart of the fuel system.” Once it malfunctions, the equipment will be unable to perform properly.

This article will explain in the simplest terms:

How to identify early signs of fuel pump failure;

How long it takes to replace a fuel pump;

How much this repair will cost.

If you don’t want to be left stranded by sudden equipment failure, keep reading!

What Are Signs of a Bad Fuel Pump?

Don't let minor fuel pump issues escalate into major problems! The following symptoms are all signs of fuel pump malfunction:  

1. Difficulty starting or failure to start  

When you press the start button, does the heavy equipment make a “clunking” sound for a while without igniting? This indicates insufficient fuel supply and low oil pressure from the fuel pump.

2. Intermittent operation during runtime  

The machine suddenly “stalls”—sometimes powerful, sometimes weak, like a person running who suddenly can’t catch their breath.

3. Significant loss of power  

The excavator lacks digging power? The roller can’t push? Power output is noticeably weaker than before. This indicates unstable fuel supply from the fuel pump.

4. Sudden surge in fuel consumption

Fuel pump malfunctions can cause abnormal fuel pressure, leading to fuel waste.

5. Engine overheating or stalling

Insufficient fuel supply can also cause incomplete combustion in the engine, leading to overheating or even stalling.

Special note: These symptoms may not be obvious in the early stages, but by paying close attention to the equipment's performance, you can detect and address issues early, avoiding greater losses!

How Long Does It Take to Replace Fuel Pump?

When many people hear that the fuel pump needs to be replaced, their first reaction is: “How long will that take? Will it delay the entire day's schedule?” In fact, the time required to replace a fuel pump primarily depends on the type of equipment and the location of the fuel pump.

For smaller equipment, such as a skid steer loader, the replacement process is relatively straightforward and can typically be completed in 1 to 2 hours. For example, if you are using a Cat skid steer fuel pump, the replacement process usually does not take too long and is relatively convenient.

However, for medium-sized equipment like standard loaders or bulldozers, the internal space is slightly more complex. The replacement process requires caution and typically takes 2 to 3 hours.

For large equipment like mining trucks or tracked excavators, the fuel pump may be deeply embedded, requiring technicians to remove several components before accessing it. In such cases, the replacement time may exceed 4 hours or even longer.

Additionally, some models are designed to be very compact, making disassembly and installation difficult. Such fuel pumps may be installed deep within the fuel tank, requiring oil drainage or the removal of multiple components during replacement, further extending repair time.

How Much Does It Cost for a Fuel Pump Replacement?

Let's be honest, besides how long it takes to repair, what everyone is most concerned about is—how much does this thing cost? The cost of replacing a fuel pump is mainly divided into two parts: parts cost and labor cost.

1. Fuel pump body price

Let’s start with the price of the fuel pump itself. If you’re purchasing a standard replacement part, the price typically ranges from $150 to $400. However, if you opt for a brand-name OEM part or a more durable high-performance model—such as a diesel fuel pump designed for heavy-duty equipment—the cost can exceed $800. As a result, many users research “diesel fuel pump price” online beforehand to estimate their budget or compare differences between brands.

2. Labor Costs

As for labor costs, different repair locations have varying rates. Ordinary repair shops charge around $100 to $150 per hour, while authorized service stations typically charge between $150 and $200 per hour. If the fuel pump is difficult to access—for example, if it’s installed deep inside the fuel tank and requires draining the fuel and removing the housing first—the labor costs will naturally be higher.

Overall, the total cost of replacing a fuel pump ranges from $300 to $1,500, depending on your equipment type, the parts selected, and the complexity of the repair.