Exploring Fuel Pump Replacement In 2003 Explorers

If you're looking to replace the fuel pump in your 2003 Ford Explorer, you've come to the right place. This is a job that can be done in a few hours and will cost you a few hundred dollars at most. You'll need to get your hands on a replacement fuel pump, either from a dealership or an auto parts store, and be prepared to get your hands dirty as you'll be working with your vehicle's fuel system.

Removing the fuel tank

To remove the fuel tank from a 2003 Explorer, you will first need to cut an access hole. This hole should start from about the front of the passenger rear seat to the back of the passenger front seat and be about as wide as the floor. A saw can be used for this, but be careful not to cut too deep to avoid damaging any wiring or hoses. Once the access hole is cut, you will need to spray a generous amount of PB blaster on the ring to twist it and remove the fuel tank.

It is important to note that dropping the tank is not necessary, especially if you do not have access to a lift or if the tank is still about 3/4 full. There are other methods to replace the fuel pump without removing the tank, which may be a safer option for some.

Additionally, always take the necessary safety precautions when performing any vehicle maintenance or repairs. This includes wearing the appropriate protective gear, such as gloves and eye protection, and ensuring the vehicle is securely parked and stabilised before beginning any work.

If you are uncomfortable or unfamiliar with any of the procedures, it is always best to consult a professional mechanic or seek advice from a trusted source.

Buying a new fuel pump

When buying a new fuel pump for your 2003 Ford Explorer, there are a few things to keep in mind. Firstly, you'll need to ensure that the fuel pump is compatible with your specific vehicle model. This includes considering the year of manufacture, the engine size or type, and any specific sub-model of the Ford Explorer.

For example, some fuel pumps are designed for vehicles manufactured after a certain date, such as 12/10/2002, and may not be compatible with earlier models. Additionally, some fuel pumps are designed specifically for gas models and may not fit flex-fuel or sport model vehicles.

It's also important to consider the quality and durability of the fuel pump. Look for products that meet or exceed original equipment (OE) quality standards and are made with durable materials to ensure a longer life. Check for warranties and return policies, as these can indicate the manufacturer's confidence in their product.

When purchasing a new fuel pump, you may also want to consider buying a fuel pump module assembly, which includes the fuel pump and any necessary connectors or strainers. This can make the installation process easier and ensure that all components are compatible.

Finally, pay attention to customer reviews and ratings. These can give you valuable insights into the quality, performance, and ease of installation of the fuel pump.

Some specific fuel pump options that you may consider for your 2003 Ford Explorer include:

• TruGrade Fuel Pump: Various models available, including B2351M, D2060M, B2334M, and A1177EP. These pumps come with a limited lifetime warranty and are available with different pin connectors.
• Delphi Fuel Pump: Models CFG0864, CFE0431, CFG0867, CFG0865, and CFG0861 are available, with different manufacture dates and pin connectors to suit your vehicle. These pumps also come with a limited lifetime warranty.
• PHILTOP Fuel Pump: Specifically designed for 2002-2003 Ford Explorer XLT, XLS, Eddie Bauer, and Limited models with a 4.0L engine. This option has a 4.1-star rating on Amazon.
• Spectra Premium Industries Fuel Pump Assembly: This option is available on eBay and comes with a 90-day parts-only warranty.
• Bosch Fuel Pump Module: Compatible with Ford Explorer and Mercury Mountaineer 2002-2003 models, this option is available on eBay.

Cutting an access hole

To cut an access hole to change the fuel pump in a 2003 Explorer, you will need to first remove the rear passenger seat. This will give you access to the floorboard underneath, which is where you will be cutting the hole.

The floorboard in this area is reportedly very thin, so you should be able to cut through it with a saw or angle grinder. Be careful not to cut any of the wiring or hoses that are located in this area. One user recommends holding the saw on an angle to avoid cutting too deep. Another user suggests covering the bottom of the seat with something flame-retardant, such as 'cool tape', to prevent a "flare-up" from the sparks created while cutting.

The location of the hole will depend on the model of your Explorer. For a 2001 2-door Explorer Sport, one user recommends the following measurements: the cut should start from about the front of the passenger rear seat to the back of the passenger front seat, and be about as wide as the floor. The measurement from the side of the truck was taken from the wheel well cover, and the measurement from the back of the truck was taken by slipping the ruler under the seat back until it stopped and then looking straight down at the ruler.

For a 2003 Explorer, one user reports that the hole will likely be located right behind the front passenger seat. They recommend getting down on the ground and looking at the bottom of the tank where the anti-slosh is moulded in the tank. It should line up with the door gap between the front and rear doors.

Once you have cut the hole, you will need to seal it back up with a piece of metal or plastic and some sealant to keep out noise, weather, and debris.

Using a sawsall

To change the fuel pump in a 2003 Explorer using a Sawzall, you will need to first locate the fuel pump under the truck. You can do this by looking at a picture of the tank and figuring out where it is positioned. Once you have located the fuel pump, you can begin to cut an access hole using the Sawzall. Make sure to hold the Sawzall at an angle so that you don't cut too deep and damage any wiring or hoses.

The access hole should start from about the front of the passenger rear seat to the back of the passenger front seat and be about as wide as the floor. After you have cut the access hole, you will need to spray a generous amount of PB blaster on the ring to get it to twist. This will help you remove the old fuel pump. Install the new fuel pump by twisting the ring back into place and connecting any necessary wiring and hoses. Be sure to test the new fuel pump to ensure it is working properly.

Using a Sawzall to change the fuel pump in a 2003 Explorer can be a quick and efficient method, but it is important to be careful and take your time to avoid any damage to the vehicle.

Twisting the ring

Before twisting the ring, it is essential to locate it. The ring is situated on the fuel pump, which is housed within the fuel tank. To access the fuel pump, you will need to remove the fuel tank from the vehicle. This task may be challenging, and it is recommended to have assistance and the necessary tools, such as a hoist, to safely lower and support the fuel tank during the replacement process.

Once you have accessed the fuel pump, you will need to focus on the ring. The ring is typically secured tightly in place, and it may require some effort to twist and remove it. In many cases, it is beneficial to spray a generous amount of penetrating oil, such as PB Blaster, onto the ring. Allow the oil to soak for a few minutes to help loosen any rust or corrosion that may be holding the ring in place.

Using a suitable tool, such as a strap wrench or a large pipe wrench, grip the ring firmly and apply force in the counter-clockwise direction to twist and loosen it. Be cautious not to use excessive force, as this may damage the ring or the surrounding components. It is important to work patiently and persistently, as the ring may be tightly secured.

After successfully loosening the ring, you can proceed to remove it. This step will provide access to the fuel pump for replacement. Ensure you have a replacement ring or a suitable gasket to create a secure seal when installing the new fuel pump.

When reinstalling the new fuel pump, place the new or reused ring in the correct position, ensuring it is properly aligned and seated. Tighten the ring by twisting it in a clockwise direction, using a wrench or your hand, depending on accessibility. Be sure not to overtighten the ring, as this may cause damage or make future removal more difficult.

Frequently asked questions