How to Replace Fuel Pump Module Assembly 2002-2005 Ford Explorer

Introduction

In this tutorial, we will walk you through the process of replacing the fuel pump module assembly on a 2002-2005 Ford Explorer. A functioning fuel pump is essential for your vehicle's performance, as it delivers fuel to the engine. If you're experiencing issues with fuel delivery or a malfunctioning fuel gauge, replacing the fuel pump may be necessary.

Step 1: Prepare Your Workspace

• Safety First: Ensure you are on a flat, level surface. Use jack stands for safety.
• Gather Tools: You will need:
  • Flat Blade Screwdriver
  • Pry Bar
  • 13mm Wrench
  • 10mm Socket
  • 15mm Socket
  • Pliers
  • 1/2 Inch Air Impact Gun
  • Ratchet
  • Cloth Rags
  • Gloves
  • Rust Penetrant
  • Safety Glasses
  • Drain Pan
  • Jack Stands
  • Pick

Step 2: Disconnect the Battery

• Open the hood and locate the negative battery terminal (black cable).
• Use a 13mm wrench to loosen and remove the terminal end.
• Inspect the terminal for any corrosion; if present, clean it.

Step 3: Drain Fuel from the Tank

• Move to the rear of the vehicle and locate the fuel tank.
• Place a drain pan beneath the fuel inlet hose connected to the tank.
• Use a flathead screwdriver to loosen the clamp and remove the hose carefully, allowing any remaining fuel to drain into the pan.

Step 4: Support the Fuel Tank

• Place a support under the center of the fuel tank to prevent it from falling during removal.
• Prepare to remove the fuel tank straps by locating the 15mm bolts for the rear and front straps.

Step 5: Remove the Fuel Tank

• Remove the rear strap's bolt and the front strap's nut.
• Carefully lower the tank, maneuvering around the drive shaft if necessary.
• Disconnect the fuel lines and electrical harness from the fuel pump assembly, ensuring you have a collection bucket underneath for any fuel spillage.

Step 6: Access the Fuel Pump Module

• With the tank lowered, locate the locking ring on top of the fuel pump.
• Use a pick to pry off the ring carefully, then lift the fuel pump module out of the tank.
• Inspect the old pump and clean the area where the new seal will sit.

Step 7: Install the New Fuel Pump

• Place the new seal in the designated area of the fuel tank.
• Insert the new fuel pump module into the tank, ensuring it is oriented correctly.
• Reinstall the locking ring, ensuring it’s snug but not cross-threaded.

Step 8: Reconnect Fuel Lines and Electrical Connector

• Reconnect the electrical harness and fuel lines to the new pump. Listen for clicks to confirm they are secure.
• Make sure all lines are properly positioned and locked.

Step 9: Reinstall the Fuel Tank

• Carefully lift the fuel tank back into its original position, reconnecting the evap line and ensuring it's secure.
• Reinstall the fuel tank straps, starting the bolts and nuts, and snug them up.

Step 10: Reconnect the Battery and Test

• Return to the engine bay and reconnect the negative battery terminal.
• Start the vehicle and check for any leaks around the fuel pump area.
• Take the vehicle for a road test to ensure everything is functioning properly and that there are no check engine lights.

Conclusion

You have successfully replaced the fuel pump module assembly in a 2002-2005 Ford Explorer. Always remember to check for leaks and ensure all connections are secure before driving. If you encounter any issues, consult a professional mechanic. Happy driving!