Exploro Fuel Pump Replacement: A Step-By-Step Guide

Changing the fuel pump on a 2007 Ford Explorer can be a challenging task. While some people opt to cut an access hole in the floor of the car, others prefer to lower the fuel tank to reach the pump. The process involves various steps, including jacking up the car, removing wheels, disconnecting hoses and electrical connectors, and carefully lowering the tank. It is important to work with caution and have a basic understanding of car mechanics to successfully replace the fuel pump.

Dropping the tank

To drop the tank, you will need to lower it to the ground by removing the straps and pulling it out from under the car. This is the proper way to do it and is safer than cutting a hole in the floor around the wiring harness, which some people opt to do. Once the tank is dropped, you can remove the pump and clean the tank.

Disconnecting the fuel lines

First, make sure you have the necessary tools. You will need a miniature flathead screwdriver, a fuel line disconnect tool, and a 12-point 12mm deep socket. It is also recommended to have a second pair of hands to help with the process.

Start by getting the fuel tank as empty as possible. This will make it lighter and easier to work with. Then, remove the spare tire and lift the Explorer, placing it on jack stands to get it as high as possible so that the tank can be easily slid out.

Next, remove the two filler hoses going to the rear of the tank. Loosen the hose clamps and work them off. Now, place your jack under the rear of the tank to support it. There will be a plastic strap in the middle of the tank with a long 13mm bolt that needs to be removed using the wobble and long extension.

At this point, you may need to remove the driver's side rear wheel to access the connections. Lower the tank slightly, but be careful not to put any tension on the fuel lines. Disconnect the green evap line connector by squeezing the two tabs and pulling it off. Also, disconnect the electrical connector to the pump.

If you can reach the quick disconnects for the fuel lines, remove them now. If not, lower the tank a little more, but be cautious not to stretch the evap hose too far as it may break. There will be a significant amount of fuel coming out of the lines, so keep rags handy.

Now, lift the tank back up to its original position to take the strain off the two bolts on the front of the tank and remove them. Lower the tank again as far as it will go, and if needed, slide it off the jack to get enough clearance. Move the tank to the passenger side to get it off the strap, then lift the strap out of the T-slot in the driver's side frame rail, and slide the tank out from under the Explorer.

With the tank out, remove the screws holding the fuel pump sending unit in place, typically six 8mm screws. Remember the orientation of the fuel lines! Carefully work the sending unit out of the tank, being cautious not to force the fuel level float, which may need careful maneuvering to remove.

Once the sending unit is out, loosen the hose clamp holding the fuel line to the pump and disconnect the electrical connector. Remove the bolt holding the pump retaining strap in place, typically a 7mm socket size. Finally, slide the pump out of the sending unit.

Reinstallation is the reverse of the removal process. Be sure to orient the sending unit correctly during reinstallation. This detailed guide should help ensure a successful fuel pump change on your 2007 Explorer.

Removing the fuel pump assembly

To remove the fuel pump assembly from your 07 Explorer, follow these steps:

Step 1: Empty the fuel tank as much as possible

This will make the process easier and reduce the risk of fuel leakage.

Step 2: Loosen the lug nuts on the driver's side (D/S) rear wheel

Use a lug wrench to loosen the lug nuts before jacking up the vehicle.

Step 3: Jack up the rear of the vehicle and place jack stands under the spring perches

Ensure the vehicle is securely supported before proceeding.

Step 4: Jack up the front of the vehicle and place it on jack stands

This step is important for accessing the fuel tank and ensuring a stable working environment.

Step 5: Remove the driver's side rear wheel

By removing the wheel, you'll gain better access to the fuel tank and its components.

Step 6: Locate and unplug the electrical connector/plug for the fuel tank

The connector is usually located just over the rear axle on the inner frame rail. Push in a clip to release it.

Step 7: Remove the two bolts from the front of the fuel tank

These bolts are typically 17mm in size. The tank does not need to be supported at this stage.

Step 8: Support the rear of the tank with a piece of wood on a floor jack

This step ensures the tank is securely held in place during the removal process.

Step 9: Remove the bolt from the center tank strap

As you remove this 13mm bolt, the front of the tank will drop onto its mounting bracket. You can use a tie wrap through the innermost bolt hole to keep the tank from sliding.

Step 10: Pivot the tank towards the drive shaft

This step creates enough room to unhook the tank strap from the frame rail. The strap keys into the frame from the top.

Step 11: Begin lowering the rear of the tank

Lower it enough to access and disconnect the following components:

• Hose clamps holding the fill and vent hoses at the rear of the tank
• Electrical plug on top of the tank (release it by pushing in a clip)
• Evap system hose (squeeze the light gray plastic clip to release)

Step 12: Disconnect all components and lower the front of the tank

Cut the wire tie and slide it rearward. You may need to drop the tank a little more to access certain parts.

Step 13: Remove the fuel pump assembly from the tank

Remove the six bolts (typically 8mm) holding the fuel pump assembly in place. Carefully work the assembly out of the tank, being mindful of the fuel level float.

Step 14: Disassemble the fuel pump assembly

Remove the bolt holding the clamp around the fuel pump. Then, remove the hose clamps and electrical connector from the pump. Finally, slide the pump out of the assembly.

Installing the new fuel pump

To install the new fuel pump, you will need to follow these steps:

• Get the fuel tank as empty as possible.
• With the engine running, pull the fuel pump relay to release pressure from the fuel line.
• Loosen the lug nuts on the driver's side (DS) rear wheel.
• Jack up the rear of the truck as high as possible and place safety stands under the spring perches.
• Jack up the front of the truck until the wheels are just off the ground. Place on safety stands.
• Remove the DS rear wheel.
• The electrical connector/plug for the fuel tank is located just over the rear axle on the inner frame rail. Take it loose from the frame and unplug it. You must push in a clip to get it to release.
• Remove the two 17mm bolts from the front of the tank. It does not need to be supported at this time.
• Support the rear of the tank with a piece of wood on top of a floor jack.
• Remove the 13mm bolt from the center tank strap. As you do this, the front of the tank will drop onto its mounting bracket.
• Put a tie wrap through the innermost bolt hole to keep the tank from sliding rearward.
• Pivot the tank toward the drive shaft to allow enough room to unhook the tank strap from the frame rail. It keys into the frame from the top.
• Begin lowering the tank at the rear. You need to lower it until you can disconnect the following:
• The hose clamps that hold the fill and vent hoses to the rear of the tank.
• The other electrical plug on top of the tank (which also has a clip you must push to release).
• The evap system hose. This hose has a light grey plastic clip on the end that must be squeezed together to release. It has two flat areas that you can squeeze with your fingers or a pair of pliers. Be careful not to break this clip.
• Once everything is disconnected, drop the front of the tank (cutting the wire tie and sliding it rearward).
• Remove the six 8mm bolts from the fuel pump assembly and carefully work the assembly out of the tank.
• Place the fuel tank on a piece of cardboard and drag it out of the way.
• Check the sump for any dirt and clean as necessary.
• Clean and put a little Vaseline on the gasket surface to help with sealing during reassembly.
• Remove the single small screw/bolt that holds the clamp around the fuel pump.
• Remove the hose clamps that hold the pump to the regulator and unplug the electrical connector from the pump.
• The pump is now ready to be removed from the assembly. It just slides out from a "U" shaped recess on the bottom of the assembly.
• If your pump was replaced in the past, you may have the wide terminal plug installed on the assembly, or you may have a thin-to-thick terminal jumper wire. Most replacement pumps have the wider terminals.
• Remove the regulator to change the hose going from it to the fuel pipe and replace it with a new hose. Be sure to use fuel line-rated fuel injection hose clamps.
• Install the new pump with the hose, rubber insulator, and strainer/sock.
• Place the fuel tank back under the truck and use pieces of wood to raise it up evenly at the front and rear.
• Place the rear of the tank on the floor jack again and begin raising it. It can be tricky to get the fuel pump assembly to line up evenly with the hole in the top of the fuel tank, so adjust as necessary.
• When everything is reconnected, put the front of the tank up and install the innermost 17mm bolt loosely. This will hold it in place while allowing you to pivot the tank away from the frame rail to reinstall the center tank strap in its slot.
• Using the floor jack, raise the rear of the tank until it is as high as it will go. Then bolt the tank strap back in place.
• Replace the remaining 17mm tank bolt and tighten everything down.
• Install a new fuel filter.
• Make sure you have reinstalled the fuel pump relay.
• Make sure you have put everything back where it belongs.
• Put at least 5 gallons of fuel in the tank to make sure the pump is submerged.
• Turn the ignition key from OFF to ON 5 or 6 times to prime the fuel system.
• Start the engine, which may run a little rough for 15-20 seconds until all the air is out of the system.

Reattaching the tank

To reattach the fuel tank of a 2007 Explorer, follow these steps:

First, ensure the tank is empty or close to empty. Then, slide the tank back under the vehicle and hook the strap back into the T-slot. Put the tank on the jack and lift it up. Remember to install the evap line before lifting the tank all the way up. Once done, push the tank up as far as it will go to get the strap bolted back in.

If you are reattaching the tank after cutting an access panel, place a liquid gasket bead around the hatch to make it airtight. Cut, paint, and pre-drill your sheet metal/plate hatch into place. Use self-tapping screws to screw the panel down. Place a few strips of double-sided tape on the top of the panel for your carpet to stick to. Finally, place the carpet down.

If you are reattaching the tank after dropping it, follow the installation steps in reverse.

Frequently asked questions