Replacing Fuel Pump In '97 Ford Explorer: Step-By-Step Guide

The fuel pump in a 1997 Ford Explorer is located inside the gas tank. To access and replace the fuel pump, the tank must be removed from the vehicle. This process can be completed in a few hours and for under $250. The steps to replace the fuel pump include getting the tank as empty as possible, loosening lug nuts, jacking up the vehicle, removing the rear wheel, disconnecting electrical connectors, and carefully lowering the tank. Once the tank is accessible, the fuel pump assembly can be removed, and a new one can be installed. It is important to take precautions and refer to detailed instructions when performing this task to ensure a safe and successful fuel pump replacement.

Empty the fuel tank as much as possible

Emptying the fuel tank is the first step in replacing the fuel pump in a 1997 Ford Explorer. The more fuel you can remove from the tank, the easier the process will be. Here are some detailed instructions to help you complete this step safely and effectively:

• If your engine is running, leave it on. This will help to release pressure from the fuel line when you pull the fuel pump relay.
• Loosen the lug nuts on the driver's side (d/s) 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 and place on safety stands.
• Remove the driver's side rear wheel.
• Locate the electrical connector/plug for the fuel tank. It is positioned just over the rear axle on the inner frame rail. Take it loose from the frame and unplug it. You will need to push in a clip to release it.
• With the fuel tank now accessible, you can start to remove it. Begin by removing the two 17mm bolts from the front of the tank. It does not need to be supported at this stage.
• Support the rear of the tank with a piece of wood on top of a floor jack.
• Remove the 13mm bolt from the centre tank strap. As you do this, the front of the tank will drop onto its mounting bracket.
• To prevent the tank from sliding, feed a tie-wrap through the innermost bolt hole. This will also allow you to move the tank without dropping it.
• Pivot the tank towards the drive shaft. This will give you enough room to unhook the tank strap from the frame rail. The strap keys into the frame from the top.
• Start to lower the tank at the rear. You need to lower it until you can access all the components that need to be disconnected from the tank. These include: the hose clamps that hold the fill and vent hoses to the rear of the tank; the electrical plug on top of the tank (release this by pushing in a clip); and the evap system hose (this has a light grey plastic clip that must be squeezed to release – be careful not to break it).
• Once everything is disconnected, you can lower the front of the tank (cutting the wire-tie and sliding it rearward).
• Check the sump for any dirt and clean if necessary.

At this point, the fuel tank should be empty and you can continue with the next steps to replace the fuel pump.

Release pressure from the fuel line

To release pressure from the fuel line of a 1997 Ford Explorer, follow these steps:

Firstly, get the tank as empty as possible. Then, with the engine running, pull the fuel pump relay to release pressure from the fuel line. Loosen the lug nuts on the d/s 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 and place on safety stands.

Now, remove the d/s 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.

Disconnect the fuel tank's electrical connector

Disconnecting the fuel tank's electrical connector is a crucial step in changing the fuel pump in a 1997 Ford Explorer. Here is a detailed, step-by-step guide to help you through the process:

Locate the electrical connector: The electrical connector/plug for the fuel tank can be found just over the rear axle on the inner frame rail. It is important to identify this component before proceeding.

Release the connector: To release the electrical connector, you need to push in a clip. It might be a bit tricky, but apply firm and steady pressure to release it.

Unplug the connector: Once the clip is pushed in, carefully unplug the electrical connector from the frame. Ensure that you don't force it, as you don't want to damage any surrounding components or the connector itself.

Secure the fuel tank: At this point, you will need to ensure that the fuel tank is secure and won't shift or move around. You can use a piece of wood or a similar object to support the rear of the tank and keep it steady. Place this object on top of a floor jack to provide additional stability.

Disconnect other components: Before you can fully disconnect the fuel tank's electrical connector, there are a few other components that need to be addressed. These include the hose clamps that hold the fill and vent hoses to the rear of the tank, another electrical plug on top of the tank (which also has a clip that needs to be pushed to release), and the evap system hose. Work carefully and methodically to avoid any damage or spills.

Lower the fuel tank: Once all the necessary components are disconnected from the tank, you can start to lower it. Be cautious and do this in a controlled manner to avoid any accidental spills or damage to nearby parts.

Remove the fuel pump assembly: With the fuel tank lowered, you can now access the fuel pump assembly. Remove the six 8mm bolts that hold the assembly in place and carefully take it out. Again, be mindful of any fuel residue or vapors and work in a well-ventilated area.

Disconnect the fuel pump: With the fuel pump assembly removed, you can now focus on the fuel pump itself. Remove the hose clamps that hold the pump to the regulator and unplug the electrical connector from the pump. Now, the pump is ready to be taken out from the assembly.

Clean and prepare for reassembly: Before installing a new fuel pump, it is essential to clean the gasket surface and apply a small amount of Vaseline to aid in sealing during reassembly. Additionally, check the sump for any dirt or debris and clean it if necessary.

Remember to work safely and wear appropriate protective gear when handling fuel system components. Always refer to a qualified mechanic or a detailed service manual for specific instructions pertaining to your vehicle.

Remove the bolts from the front of the tank

To remove the bolts from the front of the tank, you will need to get your Ford Explorer as high as possible. You can do this by jacking up the rear of the truck and placing safety stands under the spring perches. Then, jack up the front of the truck until the wheels are just off the ground and place it on safety stands.

Now, you can remove the two 17mm bolts from the front of the tank. It does not need to be supported at this time. However, you will need to support the rear of the tank with a piece of wood on top of a floor jack.

At this point, you can remove the 13mm bolt from the centre tank strap. As you do this, the front of the tank will drop onto its mounting bracket. To prevent the tank from sliding rearward, you can put a tie-wrap through the innermost bolt hole.

Disconnect the fuel tank's hoses

Disconnecting the fuel tank hoses is a crucial step in changing the fuel pump in a 1997 Ford Explorer. Here is a detailed guide on how to do this:

Firstly, ensure that the fuel tank is as empty as possible. This is important for safety reasons and will make the process of disconnecting the hoses easier.

Next, locate the hose clamps that hold the fill and vent hoses to the rear of the tank. These can usually be found towards the rear of the tank, close to where the hoses connect to the tank. Once you have located them, use the appropriate tool to loosen and remove them. This will enable you to detach the hoses from the tank. It is important to be gentle during this process to avoid damaging the hoses or the surrounding components.

After removing the hose clamps, you will need to locate and disconnect the electrical connector on top of the tank. This is usually held in place with a clip that you must push in to release. Be careful when handling electrical components, and ensure that the engine is off and the battery is disconnected before proceeding.

In some Ford Explorers, there may also be an evap system hose connected to the fuel tank. This hose is typically held in place with a light grey plastic clip that must be carefully squeezed together to release. It is important to be gentle when handling this clip, as it can break easily.

Once all the hoses and electrical connectors have been disconnected, you can proceed to remove the fuel pump assembly from the tank. This will involve removing any remaining bolts or clamps holding the assembly in place.

Throughout this process, it is important to work carefully and patiently, taking the time to identify all the relevant components and connections. It is also crucial to prioritize your safety by wearing appropriate protective gear, such as gloves and eye protection, and ensuring the work area is well-ventilated.

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