Replacing Fuel Pump In 2002 Ford Ranger: Step-By-Step Guide

If the engine in your 2002 Ford Ranger won't start, you may need to replace the fuel pump. The fuel pump is responsible for delivering gas from the fuel tank to the fuel injectors. To replace the fuel pump, you'll need to disconnect the battery, remove the bed and tailgate, disconnect the fuel lines and electrical connectors, remove the old fuel pump, and install the new fuel pump. This process can be complex and dangerous, so unless you are very experienced in auto repair, it is recommended to leave this job to the professionals. The average cost for a Ford Ranger Fuel Pump Replacement is between $1,513 and $2,106, but can vary depending on your location and the specific model of your car.

Disconnect the battery

Disconnecting the battery is the first step in changing the fuel pump on a 2002 Ford Ranger. This is important to do to reduce the chance of a fire.

First, you will need to disconnect the negative battery cable using a wrench. This will ensure that the battery is completely disconnected from the vehicle's electrical system.

Next, you will need to raise the rear of the truck. Place a floor jack under the differential or center of the axle and use jack stands to support the vehicle. This will allow you to access the fuel tank and fuel pump.

Once the vehicle is securely raised and supported, you can begin the process of removing the fuel tank and replacing the fuel pump. Remember to take all necessary safety precautions when working with the fuel system to prevent the risk of fire.

Remove the tailgate

To remove the tailgate of a 2002 Ford Ranger, you will need to unbolt the two Torx-T45 bolts from the tailgate support.

First, disconnect the cables attached to the tailgate. Then, tilt the tailgate at a 45-degree angle and pull up on one side to slide it out. Pull the tailgate towards the passenger side and it will come free. Be careful, as the tailgate can be heavy and cumbersome, and you don't want to cause any scratches or dents.

To replace the tailgate handle, you will need a T27 Torx Bit and Driver, a 10mm Socket and Ratchet, penetrating oil, and white grease.

Begin by removing the eight T27 Torx bolts from the inside of the tailgate to take off the liner. Then, remove the access panel covering the handle mechanism. Next, remove the two 10mm nuts holding the tailgate handle in place and pull the handle out. Before installing the new handle, spray penetrating oil onto the mechanism and latches and apply white grease. Feed the new handle into the tailgate, securing it with the two 10mm nuts. Finally, put the access panel and liner back in place and secure them with the eight T27 Torx bolts.

Disconnect fuel lines

Disconnecting the fuel lines is a crucial step in changing the fuel pump of a 2002 Ford Ranger. Here is a detailed, step-by-step guide on how to do this safely and effectively:

Before beginning any work on your Ford Ranger's fuel system, it is imperative to prioritise safety. Working with the fuel system can be dangerous, so take all necessary precautions to prevent fires. Disconnect the negative battery cable using a wrench. This is an important safety measure to reduce the chance of a fire.

Now, you can start to access the fuel pump and fuel lines. To do this, you will need to raise the rear of the truck. Place a floor jack under the differential or centre of the axle and use jack stands under each side of the axle to support the vehicle. Remember to apply the parking brake and chock the front wheels for added safety.

Next, you will need to access the fuel tank. Loosen the clamps on the large fuel filler hose and the smaller vent hose at the fuel tank ports, using a screwdriver. If the fuel tank is over half full, it is important to drain some fuel into an approved container to reduce the risk of spillage. Once the hoses are loose, carefully remove them by pulling them off the fuel tank ports.

At this point, you will be able to access the fuel pump and the fuel lines that need to be disconnected. Place the floor jack under the centre of the fuel tank, providing support and stability. Now, carefully lower the jack and tank just enough to access the fuel lines on top of the tank. It is important not to lower it too far, as this may damage the fuel lines.

You are now ready to disconnect the fuel lines. First, remove the fuel lines from the top of the fuel pump. Be cautious, as the fuel tank may be heavy, especially if it still contains fuel. Keep the tank centred on the jack and ensure it remains stable. Once the fuel lines are disconnected, carefully lower the tank all the way down and drag it out from under the truck.

Now that the fuel lines have been successfully disconnected, you can proceed with the next steps in changing the fuel pump of your 2002 Ford Ranger. Remember to refer to a trusted repair guide for the full procedure and always work with caution when dealing with your vehicle's fuel system.

Remove the fuel tank

To remove the fuel tank from a 2002 Ford Ranger, you will first need to disconnect the negative battery cable using a wrench. Next, raise the rear of the truck using a floor jack, which should be placed under the differential or centre of the axle. Place jack stands under each side of the axle and lower the truck onto the jack stands.

If the tank is over half full, drain some of the fuel out. To do this, remove the filler hose at the tank and siphon the fuel into an appropriate container. Remove the large fuel filler hose and the smaller vent hose at the fuel tank ports by loosening the clamps with a screwdriver. Pull the hoses off the fuel tank ports.

Disconnect the fuel pump and fuel level sending unit wiring harness plug at the rear of the tank. Place the floor jack under the centre of the fuel tank, between the fuel tank support straps. Raise the jack to give the tank a little support. Remove the two bolts closest to the rear bumper using a socket. Once the bolts are out, pull the straps down and bend them towards the front of the truck, allowing the tank to be lowered without obstruction.

Lower the floor jack and tank slowly, just enough to access the fuel lines on the top of the tank. Remove the fuel lines from the top of the fuel pump. Keep the tank centred on the jack, as it is heavy and any fuel inside will make it unstable. Lower the tank all the way down and drag it out from under the truck.

Now you can remove the lock ring that seals the fuel pump in the tank. The lock ring may be a plastic cap, which can be turned counterclockwise to remove. If it is a metal ring, it has tabs around the circumference that interlock with the tabs on the tank opening. Tap the vertical tabs counterclockwise with a screwdriver and hammer to unlock the ring.

Install the new pump

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

Firstly, install a new O-ring, as well as the new fuel pump, ensuring that the fuel pump ports are facing the same direction as the old pump. This will allow for the fuel lines to be reconnected. Next, install the lock ring by turning it clockwise. Place the fuel tank on the floor jack and push it under the truck.

Once the fuel tank is in position, use the floor jack to raise it enough to install the fuel lines on the top of the fuel pump. Then, raise the fuel tank all the way up to the bottom of the truck bed. Install the two hoses on the tank ports and tighten the clamps. Bend the fuel tank straps around the bottom of the tank and into place. Install the bolts and tighten them.

Finally, remove the floor jack. Connect the fuel pump electrical connector. Place the floor jack under the differential and lift it enough to remove the jack stands and lower the truck.

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