Exploring The 2002 Explorer: Fuel Pump Replacement Time

Replacing the fuel pump on a 2002 Ford Explorer can be a moderately complicated job. The fuel pump is located inside the fuel tank, and to access it, one would need to remove the fuel tank or look for an access panel inside the vehicle above the fuel pump. The process involves various steps, including disconnecting the negative battery terminal, jacking up the rear of the car, and loosening various clamps and hoses. The time taken to change the fuel pump can vary, with some sources estimating around two hours for labour. The cost of the fuel pump itself can range from $100 to $395, while the labour cost can be around $150.

Disconnect the negative battery terminal

Disconnecting the negative battery terminal is an important first step when changing the fuel pump on a 2002 Ford Explorer. This is because it interrupts power to the vehicle's electrical system.

• Release the clips and remove the battery access cover.
• Ensure the positive battery terminal cover is in place. This will prevent damage from a short to the positive terminal when you remove the negative battery cable clamp.
• Loosen the nut on the negative battery cable clamp, but do not remove it. It is important not to pry on the terminals, as this can cause component damage. Position the negative battery cable to the side. The torque should be 48 lb.in (5.4 Nm).
• If your vehicle is a hybrid, you will also need to remove the bolt and position the negative battery cable aside. The torque for this step is 62 lb.in (7 Nm).
• Now you have successfully disconnected the negative battery terminal!

It is important to note that when you reconnect the battery, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. You may need to drive the vehicle to allow the PCM to relearn the adaptive strategy values.

Jack up the rear of the car

Jacking up the rear of your car is a necessary step to access the fuel pump on your 2002 Explorer. Here is a detailed, step-by-step guide on how to do it safely and effectively:

Park on a Stable Surface

It is crucial to park your car on a stable and flat surface, such as a concrete driveway or a garage floor. Avoid attempting to jack up your car on uneven or soft ground, as it may cause the car to become unstable and potentially damage the vehicle. Ensure there are no hazards or moving vehicles nearby.

Use Wheel Chocks

Before jacking up the car, use wheel chocks, wooden wedges, or bricks in front of each wheel on the opposite end of the car you will be lifting. This will prevent the car from rolling forward or backward. Chock the front wheels if you are lifting the rear, and vice versa.

Put the Car in "Park"

Ensure the car is in "Park" if it has an automatic transmission. If you have a manual transmission, put the car in the lowest gear possible. This will prevent the car from rolling when you lift it.

Locate the Jack Point

Refer to your owner's manual to locate the jack points on your 2002 Explorer. There should be jack points on each side of the vehicle, behind the front wheels, and in front of the rear wheels, typically near the rocker panels. These jack points are flat metal areas, often with notches designed to fit the top of the jack.

Position the Jack

Slide the jack right below the jack point at the rear of the car. Ensure it is properly positioned and facing the correct direction. The jack point is usually located near the rear differential.

Lift the Vehicle

Start lifting the jack until it makes contact with the underside of the vehicle. Continue jacking until the rear corner of the car starts to lift off the ground. You may need to adjust the jack's position slightly to ensure proper alignment with the jack point. Stop lifting when you have enough clearance to access the fuel pump.

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 support the car. Place the jack stands under the axle or the vehicle's frame. Ensure they are securely locked in place before proceeding.

Secure the Vehicle

Before going underneath the car, give the vehicle a firm shake or wiggle to ensure it is secure and won't shift or fall off the jack or stands. You can also try pushing against the car from different angles to test its stability.

Access the Fuel Pump

Once the car is securely lifted and supported, you can crawl under the rear of the vehicle to access the fuel pump. Remember to follow the necessary safety precautions and refer to a repair manual for specific instructions on replacing the fuel pump on your 2002 Explorer.

Remember to work with a helper whenever possible, and never place any part of your body under the vehicle while it is lifted. Always follow the instructions provided in your owner's manual for jacking up your specific vehicle model.

Remove the fuel tank

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

Firstly, siphon as much fuel as possible to reduce the weight of the tank. Next, disconnect the negative cable from the battery. Then, you'll need to disconnect the hoses from the fill tube and the vent tube from the tank. Remove any visible hoses on the outside of the tank and label them if necessary.

Some models have a skid plate that covers the tank, so if this is the case, remove the skid plate supporting the tank. Disconnect the electrical connectors and fuel lines. There may be an access panel under the rear seat, but if not, there are two bands that hold the tank in place. Loosen the straps but do not drop the tank.

Lower the tank, supporting it to prevent it from falling. You will need to gain access to the fittings and connector. A tool will be required to remove the fuel lines. Once disconnected, lower the tank slowly, checking for any obstructions. If there is an evap canister mounted to the tank, this will also need to be removed.

To access the fuel tank, you may need to jack up the rear of the car and place jack stands near the rear wheels. You will also need to loosen the transmission crossmember and remove the mounting straps holding the tank in place. Be sure to relieve the fuel pressure and disconnect the fuel filter lines, filler hose, and vent lines before lowering the tank.

When lowering the tank, be mindful of any hoses that may need to be unhooked. There are electrical connectors and fuel hoses that must be removed to access the fuel pump. The fuel hose fittings can be removed by prying apart the red plastic lips on the latch with a small screwdriver.

Finally, the fuel pump can be unscrewed and removed, but be careful not to drop anything into the tank!

Disconnect the fuel pump

Disconnecting the fuel pump on a 2002 Ford Explorer involves a series of steps that require some mechanical knowledge and tools. Here is a detailed guide on how to do it:

Secure the Vehicle:

• Park the car on a level surface and engage the parking brake.
• Disconnect the negative battery terminal to prevent any accidental electrical issues.
• Jack up the rear of the car using a floor jack, and place jack stands near the rear wheels for added stability.
• Lower the floor jack and ensure the car is secure by wiggling it gently.

Access the Fuel Tank:

• 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 with a suitable tool, such as a 15mm deep socket, and pull the hose off the tank.
• Locate the forward-leading hose from the electric valve and disconnect it as well.
• Place a piece of plywood between the floor jack and the fuel tank to prevent damage to the thin plastic tank.
• Gently jack up against the tank to transfer its weight from the mounting straps to the jack.
• If necessary, drain some fuel by placing a pan under the hose fitting and using a tool to open the check valve.

Remove Mounting Straps:

• Use a 15mm deep socket to remove the forward mounting strap.
• For the rear mounting strap, you may need to unbolt the drive shaft using a 12-point 12mm socket.
• Place the transmission in park to remove the first two bolts, then neutral to rotate the U-joint for the other two bolts.
• Use a 5/8" universal joint socket to remove the 15mm bolt.
• Use brute force to get the mounting strap end down between the tank and the drive shaft.

Lower the Fuel Tank:

• Once the mounting straps are removed, lower the jack until the rear end of the tank is on the ground.
• As you lower the tank, look for any hoses that may need to be unhooked.
• There are two electrical plugs and two hoses that must be disconnected to access the fuel pump.

Disconnect the Fuel Pump:

• The fuel hose fittings have an O-ring seal and an annular ridge for locking.
• The black fuel hose connectors have a U-shaped red plastic piece that slides in a slot to lock the connector.
• To release the fitting, use a small screwdriver to pry apart the red plastic lips on the latch and 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.

At this point, you have successfully disconnected the fuel pump on your 2002 Ford Explorer. Remember to work carefully and refer to a repair manual or seek assistance from a qualified mechanic if needed.

Replace the fuel pump

Step 1: Prepare the Car

• Disconnect the negative battery terminal.
• Jack up the rear of the car with a floor jack, lifting under its differential with a plywood pad.
• Set two jack stands near the rear wheels.
• Lower the floor jack and wiggle the car to ensure it's secure.
• Crawl under the car and loosen the spiral clamp holding the rubber fuel fill hose at the rear of the gas tank. Pull the hose off the tank.
• Pull the forward-leading hose from the electric valve located nearby.
• Set up the floor jack under the fuel tank, placing a piece of plywood between the jack and the fuel tank to prevent damage to the thin plastic.
• Jack up gently against the tank to transfer the weight of the tank from the mounting straps to the jack.
• If there is a lot of fuel in the tank, drain some by placing a pan under the hose fitting and using a chopstick to open the check valve.
• Remove the mounting straps using a 15mm deep socket for the forward strap and a 12mm socket for the rear strap.
• Lower the jack until the aft end of the tank is on the ground.

Step 2: Remove the Fuel Pump

• Look for any hoses that need to be unhooked as the tank descends and unhook them.
• Remove the two electrical plugs and two hoses that are connected to the fuel pump.
• Pry apart the two red plastic lips on the latch end of the gate with a small screwdriver and 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.
• Unscrew the securing ring that secures the fuel pump in the tank using a large screwdriver and a large hammer against the lugs.
• Remove the fuel pump/gas gauge sender.

Step 3: Install the New Fuel Pump

• Put dielectric grease on the sealing ring, securing ring threads, and the securing ring surface that will contact the top of the new pump.
• Paint some dielectric grease onto each electrical pin using a small artist's paintbrush.
• Hold the new fuel pump down into the tank with a screwdriver while putting the securing ring on.
• Screw the securing ring down until it is within two inches of the original position.

Step 4: Reassemble the Car

• Put everything back together, performing the front half of the process in reverse.
• Change the fuel filter without jacking up the car. It is located behind the passenger's front wheel.
• Remove the aluminium heat deflector with a ratchet wrench.
• Remove the plastic shield and the filter bracket with a socket and an open-end wrench.
• Disconnect the three hoses, two of which are the same type as at the fuel pump, and one that uses a special tool.

Tips

• The average national cost for a fuel pump replacement across all vehicles is between $611 and $894, including parts and labour.
• It is recommended to take your car to a service centre that works on Ford vehicles.
• It will take a shop around 2 hours to replace the fuel pump, costing around $150 for labour and $395 for the pump.
• It is best to take your car in with as little fuel as possible to save on an additional charge to pump out the fuel and remove the tank.

Frequently asked questions