Replacing Fuel Pump In 2003 Ford Sport Trac: Step-By-Step Guide

If you're looking to change the fuel pump on your 2003 Ford Sport Trac, you'll first need to identify whether it needs to be replaced. Signs of a failing fuel pump include a car that won't start or stalls after starting, a slowly starving fuel flow causing the check engine light to come on, or a whirring sound coming from your fuel tank. Once you've identified that the fuel pump needs to be replaced, you can opt to take your car to a mechanic or dealership, or attempt to replace it yourself. If you choose to replace it yourself, you will need to drop the fuel tank and remove the old fuel pump, which is located inside the fuel tank, through the top of the tank via an access panel in the passenger compartment or by removing the tank from the vehicle. This is a moderately complicated job, so it may be best left to professionals.

The fuel pump is located inside the fuel tank

To change the fuel pump on a 2003 Ford Sport Trac, you'll first need to access the pump, which is located inside the fuel tank. This means you'll need to remove the fuel tank from the vehicle or access it through an access panel in the passenger compartment. It's a moderately complicated job that may be best performed by a professional mechanic or at a dealership's service department.

• Prepare the Vehicle: Start by parking the vehicle on a level surface and engaging the parking brake. Remove the negative battery cable to prevent any accidental electrical shorts during the repair process. Next, locate the fuel tank and determine how to safely remove it. You may need to refer to a repair manual for your specific vehicle model. Place a suitable container under the fuel tank to catch any spilled fuel during the removal process.
• Drain the Fuel Tank: Before removing the fuel tank, it's essential to drain the fuel to reduce the risk of fire and make the tank lighter and easier to handle. Use a siphon pump or a similar tool to drain the fuel into an approved fuel storage container.
• Remove the Fuel Tank: Once the fuel is drained, proceed to remove the fuel tank. This process may vary depending on your vehicle's specific design. Refer to a repair manual or seek guidance from a professional mechanic if needed. Be cautious when handling the fuel tank to avoid damaging any fuel lines or electrical connections.
• Access the Fuel Pump: With the fuel tank removed or accessed through the passenger compartment, you should now be able to locate the fuel pump inside the tank. It is likely submerged in the fuel to keep it cool and is connected to the fuel lines and electrical wiring.
• Disconnect the Fuel Pump: Before removing the old fuel pump, carefully disconnect it from the fuel lines and electrical wiring. Take note of how the pump is connected to ensure proper installation of the new pump. Some pumps may have a retaining ring or clamps that need to be removed first. Again, refer to a repair manual or seek professional assistance if needed.
• Install the New Fuel Pump: Obtain a compatible replacement fuel pump and install it in the reverse order of removal. Ensure all connections are secure and properly sealed to prevent fuel leaks. Reattach any mounting hardware or brackets that were previously removed.
• Reinstall the Fuel Tank: Carefully lift the fuel tank back into position and secure it according to the vehicle's specifications. Reconnect the fuel lines and electrical connections, ensuring they are properly seated and clamped. Reattach any shielding or components that were removed during the process.
• Refill the Fuel Tank: With the new fuel pump installed and the fuel tank secured, refill the fuel tank with the appropriate type and amount of fuel for your vehicle.
• Reconnect the Battery: Reconnect the negative battery cable and ensure that all connections are secure. Start the vehicle and check for any signs of fuel leaks or unusual noises.

Remember, working on fuel systems can be dangerous due to the risk of fire or fuel leakage. Always exercise extreme caution and refer to reliable repair resources or seek professional assistance if you have any doubts about the procedure.

You may need to cut an access hole to reach the pump

Cutting an access hole to reach the fuel pump of a 2003 Ford Sport Trac may be necessary if you are unable to drop the tank or perform the repair from above. Here is a guide on how to do it:

First, make sure you have the necessary tools and safety equipment, such as gloves and eye protection. You will also need a way to cut the hole, such as a grinder, tin snips, or an air chisel. It is important to choose a tool that will not create sparks, as this could be dangerous when working with fuel.

Next, locate the fuel pump by looking for the circular indentation near the low point of the tank. This is usually behind the front passenger seat, close to the chassis rail. Mark the area you will be cutting with tape or a marker.

Before you begin cutting, it is important to take precautions to minimize the risk of fire or injury. Make sure the vehicle is turned off and the fuel tank is as empty as possible. If there is fuel in the tank, use a siphon to remove as much as you can.

Now, you can start cutting the hole. Use your chosen tool to carefully cut through the marked area. Take your time and be cautious not to cut yourself on the sheet metal. Cut a hole that is just large enough to access the fuel pump and reach the necessary components.

Once the hole is cut, use a fuel line tool to disconnect the fuel lines and remove the old fuel pump. Install the new fuel pump and reconnect the fuel lines. Test your work by starting the vehicle and checking for any leaks.

Finally, patch up the hole you cut in the floor. You can use a piece of cardboard or metal as a temporary solution, but it is best to create a more permanent patch using a new piece of sheet metal.

You will need to drop the fuel tank

To change the fuel pump on a 2003 Ford Sport Trac, you will need to drop the fuel tank. The fuel pump is located inside the fuel tank, and you will need to access it from the top of the tank.

Before you begin, disconnect the battery and release the fuel pressure. You will also need to drain the fuel tank or lower it with fuel still in it. If you are working on your back, use a floor jack and a friend to support the tank while lowering it.

Step 1:

Jack up the rear of the vehicle securely and support it with jack stands. Remove the left rear wheel and fender liner. Loosen the hose clamps on the filler and breather tube at the tank end. Orient the clamp bonding patch with the top of the tank and spray between the hose and tube with window spray (silicone). Twist the hose a little.

Step 2:

Remove the three screws at the filler cap to allow movement of the filler tube. You can choose to take it out after the hose is removed for more room.

Step 3:

Remove the tank shield (there are usually four bolts). Loosen the tank bolts at the front of the tank, but do not take them all the way out yet; just leave them loose.

Step 4:

Support the rear of the tank with a jack and plywood (12x12). Remove the strap bolt and lower the rear of the tank. You can now siphon the fuel out if you haven't done so already.

Step 5:

Lower the tank a little more and disconnect the fuel lines and wiring from the rear tire area.

Step 6:

Remove the two bolts at the front and slide the tank back to clear the crossmember. Lower the jack and ease the tank onto a mat or old rug.

Once the tank is down, you can remove the fuel pump and proceed with the necessary repairs or replacements.

A special tool may be required to remove the hold-down ring

When removing the hold-down ring of a fuel pump on a 2003 Ford Sport Trac, you may need to use a special tool. This is because the hold-down ring can be challenging to remove and requires a significant amount of force to loosen and detach. While some people have reported success using a flat screwdriver and a hammer, it is important to exercise caution when working around gasoline to avoid creating sparks that could potentially cause an explosion. Instead, it is recommended to use a brass punch and a brass mallet or a deadblow hammer. Alternatively, a wooden dowel can be used to remove the hold-down ring safely.

To remove the hold-down ring, identify the curved side and hit it in the opposite direction with the brass punch and hammer. It may take a few firm blows to loosen the ring, but it will eventually turn. Be sure to vent the tank by removing the cap to relieve any remaining pressure inside before attempting to remove the ring. Once the ring is loose, turn it counter-clockwise to unscrew it. When putting the ring back on, you may need to press down on the fuel pump lid moderately, as the springs on the ring may make it longer than the tank is deep.

Additionally, when working on the fuel pump, it is important to drain the fuel tank or lower it with a floor jack and a friend's assistance to support the tank. This will provide access to the pump and allow for easier removal and installation.

Disconnect the fuel pump electrical connector

Disconnecting the fuel pump electrical connector is a crucial step in changing the fuel pump on a 2003 Ford Sport Trac. Here is a detailed guide on how to do this:

Before beginning any work on your vehicle, it is important to take the necessary safety precautions. Make sure the car is parked on a flat, level surface and engage the parking brake to prevent accidental movement. It is also recommended to wear protective gear, such as gloves and eye protection, to shield yourself from any potential hazards.

To begin disconnecting the fuel pump electrical connector, locate the fuel tank. The fuel pump is positioned inside the fuel tank, so you will need to gain access to it. This may involve removing the rear seat or a panel in the passenger compartment, or in some cases, lowering or removing the fuel tank itself. Refer to your vehicle's repair manual or seek guidance from a qualified mechanic if you are unsure about the specific procedure for your car.

Once you have accessed the fuel tank, identify the fuel pump electrical connector. It should be located near the fuel pump and is responsible for supplying power to the pump. Before disconnecting any electrical components, it is crucial to disconnect the negative battery cable to prevent any accidental electrical shorts.

Now, carefully disconnect the electrical connector from the fuel pump. The connector may have a locking mechanism or clips that need to be released before separation. Gently pull the connector away from the fuel pump, ensuring that you do not damage any wires or components. Inspect the connector for any signs of corrosion or damage. If the connector or its wires appear damaged, it is recommended to replace them to ensure reliable electrical connections.

After disconnecting the fuel pump electrical connector, set it aside in a safe place where it will not be disturbed. Ensure that the connector is properly secured and will not accidentally reconnect during the remainder of the fuel pump replacement process.

At this point, you have successfully disconnected the fuel pump electrical connector. You can now proceed with the next steps in changing the fuel pump, such as removing the old pump and installing the new one. Remember to work carefully and refer to reliable sources or seek professional assistance if you encounter any unfamiliar procedures or complex tasks.

Frequently asked questions