Exploring Fuel Pump Replacement: 2002 Explorer Edition

The fuel pump in a 2002 Ford Explorer is located inside the fuel tank and helps to ensure that pressurised gasoline flows to the engine to power the vehicle. While fuel pumps can last a long time, they sometimes need to be replaced. The cost of replacing a fuel pump varies depending on the grade of the part and the labour involved. The process of changing a fuel pump is complex and involves multiple steps, and it is recommended that you get it done at a dealership's service department or by an experienced mechanic.

Disconnect the negative battery terminal

Disconnecting the negative battery terminal is a critical safety precaution when working on a car. The negative terminal, also known as the ground strap or cable, is directly connected to the vehicle's engine, body, and chassis. Disconnecting it first before the positive terminal is essential to prevent accidents or damage to the vehicle's electrical system.

"First, following everyone’s advice, I disconnected the negative battery terminal. Then I jacked up the rear of the car with a floor jack, lifting under its differential (with a plywood pad) and set two jack stands near the rear wheels. I lowered the floor jack, then seriously wiggled the car to be sure it was secure. I crawled under the car and loosened the spiral clamp holding the rubber fuel fill hose at the rear of the gas tank and pulled it off. There is also a forward-leading hose from the electric valve located nearby that needs to be removed.

Next, set up the floor jack under the fuel tank with a piece of plywood between the jack and fuel tank to prevent damage to the thin plastic fuel tank from the lugs sticking up on the jack. Gently jack up against the tank to transfer the weight of the tank from the mounting straps to the jack. The tank is easier to handle with less fuel in it.

Now, lower the jack until the aft end of the tank is on the ground. As you lower the tank, be mindful of any hoses that may need to be unhooked. There are two electrical plugs and two hoses that must be removed to access the fuel pump. They are obvious and need to be disconnected. The plugs have a release mechanism that may be tricky to find, but keep looking as it will eventually give way.

The fuel hose fittings slip onto their pipes with an o-ring to seal and an annular ridge to lock them in place. To remove the fittings, you need to open the red plastic gate by prying apart the two red plastic lips with a small screwdriver and swinging the gate open. Then, work the red plastic sliding lock piece back and away from the ridge to release the fitting. This can be tricky, so be patient and use a screwdriver to alternately push on the hinge and lip sides of the red plastic piece until it slides out.

Finally, unscrew the securing ring that holds the fuel pump in place using a large screwdriver and a hammer against the lugs. Mark the securing ring with a marker to ensure you can tighten it back to the same position when installing the new pump."

Remember to always wear safety gear, such as gloves and safety glasses, and remove any jewellery before beginning work. Additionally, it is recommended to have backup power connected to your car before disconnecting the battery to prevent data loss in your car's computer system.

Jack up the rear of the car

Jacking up the rear of a car is a necessary step when performing maintenance on your vehicle. Here is a detailed guide on how to do it safely and correctly for a 2002 Ford Explorer:

Park on a Stable Surface:

Ensure you park your Ford Explorer on a stable and flat surface, such as a concrete driveway or garage floor. Avoid jacking up your vehicle on unstable ground or on the road.

Use Wheel Chocks:

Place wheel chocks, wooden wedges, or bricks in front of each front wheel. This will prevent the vehicle from rolling forward when you lift the rear.

Put the Car in "Park":

Make sure the car is in "Park" or, if it has a manual transmission, put it in the lowest gear. This adds an extra layer of security to prevent the car from moving.

Locate the Jack Point:

Refer to your owner's manual to locate the jack points on your Ford Explorer. There are usually jack points on each side behind the front wheels and in front of the rear wheels, close to the rocker panels.

Position the Jack:

Slide the jack below the jack point at the rear of the vehicle. Ensure it is properly positioned with the correct side facing up.

Raise the Jack:

Start raising the jack. You may need to make final adjustments to its position as you lift to ensure proper alignment with the jack point. Continue jacking until the rear of the car is lifted and you have enough clearance to access the fuel tank.

Use Jack Stands:

For added safety, use jack stands or wheel cribs to support the weight of the vehicle. Never rely solely on the jack to hold the weight of the car. Place the jack stands under the axle or the rear differential.

Now that the rear of your 2002 Ford Explorer is securely jacked up, you can proceed with the fuel pump replacement, following the steps outlined in the forum post you provided. Remember to work cautiously and refer to your service manual for detailed instructions on replacing the fuel pump.

Remove the fuel tank

To remove the fuel tank from a 2002 Ford Explorer, you'll need to follow these steps:

First, disconnect the negative battery terminal. Jack up the rear of the car and place jack stands near the rear wheels. Crawl under the car and locate the rubber fuel fill hose at the rear of the gas tank. Loosen the spiral clamp holding the hose and pull it off. There should also be a forward-leading hose from the electric valve nearby—remove this as well.

Place a floor jack under the fuel tank, using a piece of plywood between the jack and the tank to prevent damage to the thin plastic fuel tank. Gently jack up against the tank to transfer the weight from the mounting straps to the jack. It's easier to handle the tank with less fuel in it, so consider draining the fuel beforehand.

Remove the mounting straps holding the tank in place. The forward mounting strap can be removed with a 15mm deep socket, while the rear mounting strap bolt is at a bad angle and may require unbolting the drive shaft for better access.

Once the mounting straps are removed, lower the jack until the rear end of the tank is on the ground. You may need to unhook some hoses as the tank descends, and there are two electrical plugs and two hoses that must be removed before you can take out the fuel pump.

Before removing the fuel pump, make sure to relieve the fuel pressure. Disconnect the fuel filter lines at the front end of the tank, as well as the filler hose and vent lines at the rear. Be careful when removing the plastic fitting connectors, especially the one at the rear that needs to be pressed in to expand and remove it from the tank.

Finally, lower the tank and remove it from the vehicle. This process should take around an hour if you have some experience, but it may take longer if it's your first time.

Disconnect the fuel pump's electrical plugs and hoses

Disconnecting the fuel pump's electrical plugs and hoses is a crucial step in changing the fuel pump on a 2002 Ford Explorer. Here is a detailed guide on how to approach this task:

Firstly, ensure that you have the necessary tools and safety equipment. This includes a floor jack, jack stands, a small piece of wood for the fuel tank, a ratchet and metric sockets in various sizes, a screwdriver, and a hammer. It is also recommended to wear safety gear such as gloves and eye protection.

Now, let's begin the process:

• Disconnect the negative battery terminal to ensure safety.
• Jack up the rear of the car and secure it with jack stands. Place the jack stands near the rear wheels for stability.
• Crawl under the car and locate the fuel tank. You will find two electrical plugs and two hoses connected to the fuel pump.
• Identify the release mechanisms for the electrical plugs. They might be a bit tricky to find, so take your time and be patient.
• Disconnect the electrical plugs from the fuel pump. Pay attention to the orientation of the plugs as you will need to reconnect them later.
• Locate the fuel hose fittings. They will have an O-ring seal and an annular ridge on the pipe.
• To remove the fuel hose fittings, you will need to release the locking mechanism. The black fuel hose connectors have a unique design with a U-shaped piece of red plastic.
• Pry apart the two red plastic lips on the latch end of the gate using a small screwdriver. Swing the gate open.
• Work the red plastic sliding lock piece back out of the black plastic part and away from the ridge to release the fitting. You may need to alternate pushing on the hinge side and the lip side with the screwdriver.
• Once the red plastic piece is far enough out, slide the fuel hose fitting off the pipe.
• At this point, you have successfully disconnected the electrical plugs and hoses from the fuel pump.

Remember to work carefully and methodically to avoid any damage to the vehicle or injury to yourself. Take breaks when needed and ensure you are comfortable and confident with each step before proceeding.

Unscrew the securing ring

To unscrew the securing ring that holds the fuel pump in the tank, you will need a large screwdriver and a large hammer. Place the screwdriver against the lugs on the securing ring and gently tap it with the hammer until the ring starts to move. Keep tapping until you can turn the ring with your fingers. Before you start, mark the ring with a marker so you can see how much it has moved and so you can get it back to approximately the same tightness later.

The securing ring can be tight, so be prepared to use some force to get it moving. It may also be necessary to hold the fuel pump down into the tank with a screwdriver while you put the securing ring back on, as the pump assembly is spring-loaded to keep the suction firmly down onto the tank floor.

Make sure you don't drop anything into the tank while you're working!

Frequently asked questions