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

Changing the fuel pump on a 2004 Ford Explorer can be a complex task. Before attempting to replace the fuel pump, it is important to ensure that the fuses and relays are functioning correctly. The process involves releasing the fuel system pressure, draining the tank, removing the fuel tank skid plates, and supporting the fuel tank with a jack. The fuel pump retaining lock ring must be carefully rotated using a fuel pump locking ring tool, and the old O-ring seal should be discarded. When installing the new fuel pump, it is crucial to use the items provided in the kit, especially the new O-ring seal. It is also important to note that fuel pump replacement may not always solve the issue, as other factors such as fuel pressure and the fuel pressure regulator should also be considered.

Prepare your vehicle for fuel pump servicing

To prepare your 2004 Ford Explorer for fuel pump servicing, you should first position your vehicle on a hoist and place it in neutral. Then, release the fuel system pressure and drain the tank.

Next, remove the fuel tank skid plates with a socket wrench and use a jack to support the fuel tank. Take out the strap bolt for the fuel tank with a socket wrench, and then remove the fuel tank and disconnect the vapor tube fitting.

Now, you can release the fuel pump retaining lock ring by carefully rotating it using a fuel pump locking ring tool. Be sure to remove the lock ring first, followed by the fuel pump. Take care to avoid damaging the fuel filter and float arm. Finally, discard the old O-ring seal.

Release the fuel system pressure and drain the tank

To release the fuel system pressure and drain the tank of your 2004 Ford Explorer, follow these steps:

Firstly, get the tank as empty as possible. With the engine running, pull the fuel pump relay to release pressure from the fuel line. 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 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.

Now, remove the two 17mm bolts from the front of the tank. It does not need to be supported at this time. 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.

At this point, you can pivot the tank towards the drive shaft to allow enough room to unhook the tank strap from the frame rail. It keys into the frame from the top. Begin lowering the tank at the rear. You need to lower it until you can access and disconnect the following:

• The hose clamps that hold the fill and vent hoses to the rear of the tank.
• The other electrical plug on top of the tank (push in a clip to release).
• The evap system hose (squeeze together a light grey plastic clip on the end to release).

Once all the items are disconnected from the tank, you can drop the front of the tank (cutting the wire tie and sliding it rearward).

Now, you can remove the six 8mm bolts from the fuel pump assembly and take the assembly out of the tank. Place the tank on a piece of cardboard and drag it out of your way. Check the sump for any dirt and clean as necessary.

Finally, you can drain the tank.

Remove the fuel tank skid plates and support the tank with a jack

To remove the fuel tank skid plates and support the tank with a jack, you will need a socket wrench and a jack.

First, use the socket wrench to remove the fuel tank skid plates. Once they are removed, carefully place the jack underneath the fuel tank to support its weight. It is important to ensure that the jack is secure and can bear the weight of the tank to avoid any accidents.

Now that the jack is in place, you can begin the process of lowering the fuel tank. This will involve removing the strap bolt for the fuel tank with a socket wrench. Once the bolt has been removed, you can carefully lower the tank, being mindful of any hoses or wires that may be connected to it.

At this point, you should be able to access the fuel pump and begin the process of replacing it. Remember to work carefully and methodically to avoid any damage to the surrounding components, especially the fuel filter and float arm.

Take out the strap bolt for the fuel tank, remove the tank and disconnect the vapor tube fitting

To take out the strap bolt for the fuel tank, remove the tank, and disconnect the vapor tube fitting of a 2004 Ford Explorer, follow these steps:

First, get the tank as empty as possible. With the engine running, pull the fuel pump relay to release pressure from the fuel line. Loosen the lug nuts on the driver-side 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-side 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 by pushing in a clip to release it. Remove the two 17mm bolts from the front of the tank. It does not need to be supported at this point.

Support the rear of the tank with a piece of wood on top of a floor jack. Remove the 13mm bolt from the center tank strap. As you do this, the front of the tank will drop onto its mounting bracket. Put a zip tie through the innermost bolt hole to keep the tank from sliding backward. This will allow you to move the tank without dropping it.

Begin lowering the tank at the rear. You need to lower it until you can access all the parts that need to be disconnected from the tank:

• The hose clamps that hold the fill and vent hoses to the rear of the tank.
• The other electrical plug on top of the tank, which also has a clip that must be pushed to release it.
• The evap system hose, which has a light gray plastic clip on the end that must be squeezed to release it. Be careful not to break this clip.

Once everything is disconnected, drop the front of the tank by cutting the zip tie and sliding it backward.

Now, you can remove the vapor tube fitting. The evap system hose has a light gray plastic clip that must be carefully squeezed together and released.

At this point, you can remove the six 8mm bolts from the fuel pump assembly and take the assembly out of the tank. Place the fuel tank on a piece of cardboard and drag it out of the way.

Finally, to reinstall the tank, place it back under the truck and use pieces of wood to raise it evenly at the front and rear. Begin raising the rear of the tank with the floor jack until it is as high as possible. Bolt the tank strap back in place and replace the remaining 17mm tank bolt. Tighten everything down.

Release the fuel pump retaining lock ring and remove the lock ring and fuel pump

To release the fuel pump retaining lock ring, carefully rotate it using the fuel pump locking ring tool. You will need to be careful to avoid damaging the fuel filter and float arm. Once the lock ring has been removed, you can then take out the fuel pump. Make sure to discard the old O-ring seal.

• Position your vehicle on a hoist and place it in neutral.
• Release the fuel system pressure and drain the tank.
• Remove the fuel tank skid plates with a socket wrench and use a jack to support the fuel tank.
• Take out the strap bolt for the fuel tank with a socket wrench.
• Remove the fuel tank and disconnect the vapor tube fitting.
• Now, carefully rotate the fuel pump retaining lock ring using the fuel pump locking ring tool.
• Remove the lock ring, followed by the fuel pump. Be extra careful not to damage the fuel filter and float arm.
• Discard the old O-ring seal.

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