How to Replace Fuel Pump & Transfer Unit 2011-2019 Ford Explorer 3.5L

Introduction

This tutorial provides a step-by-step guide on how to replace the fuel pump and transfer unit in a 2011-2019 Ford Explorer with a 3.5L engine. Following these instructions will help ensure a successful installation, improving your vehicle's performance. This guide is particularly relevant for anyone experiencing fuel delivery issues or needing to replace a faulty fuel system component.

Step 1: Gather Necessary Tools and Materials

Before you begin the replacement process, ensure you have the following tools and materials ready:

• Pocket Screwdriver
• Pry Bar
• 10mm, 13mm, 19mm, and 8mm Sockets
• Air Blow Gun
• Trim Tool Set
• Channel-Lock Pliers
• Locking Pliers
• Needle Nose Pliers
• T45 Driver
• Ratchet and Socket Extensions
• Swivel
• Torque Wrench
• Gloves
• Marker or Writing Utensil
• Rust Penetrant
• Safety Glasses
• Wire Ties
• Brass Punch
• Chisel
• Floor Jack
• Hammer
• Jack Stands
• Pole Jack
• Wheel Chocks

Step 2: Safety Precautions

Before starting the replacement, take the following safety precautions:

• Wear safety glasses and gloves to protect yourself from debris and sharp objects.
• Ensure the vehicle is on a flat surface, engage the parking brake, and use wheel chocks.
• Disconnect the negative battery terminal to prevent electrical shorts.

Step 3: Access the Fuel Pump

1. Lift the Vehicle: Use a floor jack to lift the rear of the vehicle and secure it with jack stands.
2. Remove the Fuel Tank:
   • Locate the fuel tank straps and use the appropriate socket to remove them.
   • Carefully lower the fuel tank using a pole jack for support.
   • Disconnect any electrical connectors and fuel lines attached to the tank, using needle nose pliers if necessary.

Step 4: Remove the Old Fuel Pump

1. Locate the Fuel Pump Module: Once you have access to the top of the fuel tank, locate the fuel pump module.
2. Disconnect Electrical Connections: Use your fingers or a trim tool to gently disconnect the electrical connectors.
3. Unscrew the Module: Use the T45 driver to remove the screws holding the fuel pump module in place.
4. Remove the Fuel Pump: Carefully pull the fuel pump module out from the tank.

Step 5: Install the New Fuel Pump

1. Prepare the New Pump: Take the new fuel pump module and ensure all seals are intact.
2. Insert the New Pump: Line up the new fuel pump module with the opening in the tank and press it into place.
3. Secure the Module: Use the T45 driver to tighten the screws you previously removed, ensuring a secure fit.
4. Reconnect Electrical Connectors: Reattach the electrical connectors to the new fuel pump.

Step 6: Reinstall the Fuel Tank

1. Position the Fuel Tank: Carefully lift the fuel tank back into place using the pole jack.
2. Reconnect Fuel Lines: Make sure to connect any fuel lines and electrical connectors securely.
3. Reattach Fuel Tank Straps: Use the 10mm socket to reattach the fuel tank straps, ensuring they are tight.

Step 7: Final Checks and Testing

1. Reconnect the Battery: Reattach the negative battery terminal.
2. Turn on the Ignition: Without starting the engine, turn the ignition to the 'ON' position to prime the fuel system.
3. Check for Leaks: Inspect for any fuel leaks around the tank and pump area.
4. Start the Engine: If no leaks are detected, start the engine and let it run for a few minutes to ensure everything is functioning properly.

Conclusion

Replacing the fuel pump and transfer unit in your Ford Explorer can be a manageable DIY project with the right tools and precautions. Always remember to prioritize safety and double-check your work to avoid future issues. If you encounter any problems or are unsure, consult a professional mechanic for assistance. Happy repairing!