Replacing Fuel Tank Sending Unit In 2006 Expedition: Step-By-Step Guide

The fuel level sending unit in a car is located in the fuel tank and sends a constant signal about the amount of fuel remaining. In this case, the 2006 Ford Expedition has a fuel tank capacity of 28.0 gallons and a fuel economy of 14 MPG in the city and 17-19 MPG on the highway. While fuel level sending units rarely need to be replaced, it is possible to do so in the 2006 Ford Expedition by purchasing a new part and following the replacement instructions.

Removing the fuel tank

Step 1: Safety First

Before starting, ensure you are working in a well-ventilated area and take the necessary precautions when working with fuel. Disconnect the battery to prevent any accidental sparks.

Step 2: Prepare the Vehicle

Park the vehicle on a level surface and engage the parking brake. Place wheel chocks around the wheels for added safety.

Step 3: Drain the Fuel Tank

You will need to drain the fuel from the tank before removal. Use a siphon pump or a similar tool to carefully drain the fuel into an approved fuel storage container.

Step 4: Disconnect Fuel Lines and Electrical Connections

Locate the fuel lines and electrical connectors attached to the fuel tank. Carefully disconnect and detach these components, ensuring that you have a safe and proper way to dispose of any remaining fuel.

Step 5: Remove the Fuel Tank Straps

The fuel tank is secured by straps that need to be removed. Loosen and remove the bolts or clamps holding the straps in place, being careful not to drop them into the tank.

Step 6: Lower and Remove the Fuel Tank

With the straps removed, carefully lower the fuel tank from the vehicle. Depending on the model, you may need to access it from underneath the vehicle or through the trunk or back seat. Ensure you have assistance when handling the fuel tank, as it can be heavy and cumbersome.

Step 7: Clean the Area

Once the fuel tank is removed, clean the surrounding area, including the tank mounting points, to remove any dirt, debris, or residue.

Note: It is important to dispose of the drained fuel and any contaminated materials properly, following local regulations and safety guidelines. Always put your safety and well-being first when working on your vehicle.

Disconnecting the battery

Before starting, ensure you have gathered the necessary tools and safety equipment, such as gloves and eye protection. Working with electricity and fuel systems can be hazardous, so taking the proper precautions is crucial. It is also recommended to refer to your vehicle's repair manual for specific instructions related to your make and model.

Now, let's begin with disconnecting the battery:

• Locate the Battery: The battery is typically located in the engine compartment or, in some cases, in the trunk or under the rear seat. Refer to your owner's manual if you're unsure where it is.
• Prepare the Work Area: Once you have located the battery, identify the negative (-) and positive (+) terminals. Ensure that you have a clear and safe working area by removing any objects or obstructions around the battery.
• Disconnect the Negative Terminal: Using an appropriate-sized wrench or socket, loosen the nut or bolt connecting the negative battery cable to the terminal. Do not allow the wrench or socket to touch any other metal parts of the car, as this could result in a short circuit. Once loose, carefully remove the cable from the terminal. You may need to wiggle it gently to detach it completely.
• Disconnect the Positive Terminal: Similarly, loosen the nut or bolt connecting the positive battery cable to the terminal. Remove the cable, ensuring that it does not touch any metal surfaces that could cause a short circuit.
• Secure the Cables: After both cables are disconnected, secure them away from the battery to prevent accidental contact. You can use tape or cable ties to keep them in place.
• Verify Voltage: To ensure that the power is completely disconnected, use a voltage tester to check between the positive and negative terminals. The tester should indicate that there is no voltage or current flow.
• Additional Precautions: If you are not proceeding with the fuel tank sending unit replacement immediately, it is essential to take some extra precautions. Apply insulating tape or caps to the battery terminals to prevent accidental contact or short circuits. Keep children and pets away from the work area, and store the disconnected battery in a safe, secure place.

Remember, working with electricity and fuel systems can be dangerous, so always exercise caution and refer to a professional technician if you have any doubts or concerns.

Testing the fuel pump

To test the fuel pump of a 2006 Ford Expedition, you can perform the following steps:

Firstly, it is important to understand the function of the fuel pump and the related components. The fuel pump is responsible for delivering fuel from the tank to the engine, and it works in conjunction with the fuel pump control module, which regulates voltage to maintain proper fuel pressure.

Next, you can begin the testing process:

• Check for power at the fuel pump connector: Ensure that there is power reaching the fuel pump by testing the voltage at the connector. This can be done using a multimeter or a test light. If there is no power, check the fuses, relays, and wiring for any issues.
• Listen for the fuel pump operation: With the ignition key turned to the "on" position, you should be able to hear the fuel pump running for a brief period. If you don't hear any noise, it could indicate a faulty fuel pump or a problem with the wiring or relay.
• Check fuel pump pressure: You can use a fuel pressure gauge to measure the fuel pressure in the fuel rail. Connect the gauge to the Schrader valve on the fuel rail and observe the pressure reading. If the pressure is below specifications, it may indicate a faulty fuel pump or a blockage in the fuel system.
• Perform a bench test: If you have access to a bench testing setup, you can remove the fuel pump from the vehicle and test it outside the engine. This involves connecting the fuel pump to a power source and observing its performance, such as fuel flow rate and pressure.
• Inspect the fuel pump module: The fuel pump module, which includes the pump, sending unit, and strainer, should be examined for any signs of damage or corrosion. A faulty module can affect the performance of the fuel pump.
• Check related components: In some cases, issues with other components, such as the fuel injectors, fuel filter, or fuel pressure regulator, can impact the performance of the fuel pump. Ensure that these components are functioning properly and are not causing any restrictions in the fuel system.

Remember to refer to the specific service manual for your 2006 Ford Expedition and take appropriate safety precautions when working with fuel system components.

Replacing the fuel pump and sender assembly

Step 1: Purchase a Replacement Fuel Pump and Sender Assembly

You can buy a replacement fuel pump and sender assembly for your 2006 Ford Expedition from online retailers or your local Ford dealership. The cost of the part can range from $480 to $630.

Step 2: Prepare Your Vehicle

Park your vehicle on a level surface and engage the parking brake. Put on safety gloves and goggles. Make sure you have multiple gas cans ready to transfer the fuel from your tank.

Step 3: Drain the Fuel Tank

Remove the fuel pump relay and drain the fuel tank by siphoning the fuel into the gas cans.

Step 4: Remove the Fuel Tank

Refer to your vehicle's repair manual for the exact procedure, as it may vary depending on the model. Typically, you will need to disconnect the negative battery cable, remove the rear seat, and lower the fuel tank to access the fuel pump and sender assembly.

Step 5: Disconnect the Old Fuel Pump and Sender Assembly

Disconnect the electrical connectors and fuel lines from the old fuel pump and sender assembly. You may need to remove any retaining clips or bolts holding the assembly in place. Be careful not to damage the surrounding components.

Step 6: Install the New Fuel Pump and Sender Assembly

Position the new fuel pump and sender assembly in place, ensuring it is securely mounted and connected to the fuel lines and electrical connectors. Refer to the manufacturer's instructions for any specific torque specifications or settings.

Step 7: Reinstall the Fuel Tank and Refill Fuel

Carefully lift the fuel tank back into position and secure it according to the vehicle's specifications. Reattach the negative battery cable. Refill the fuel tank with the fuel you siphoned earlier.

Step 8: Test the New Fuel Pump and Sender Assembly

Start the engine and check for any leaks or unusual noises. Ensure that the fuel gauge is functioning correctly and that there are no warning lights illuminated on the dashboard.

Replacing the fuel tank cap

To replace the fuel tank cap of your 2006 Ford Expedition, you will need to purchase a replacement cap that is compatible with your vehicle. You can source this directly from Ford or opt for a third-party manufacturer.

Park your vehicle on a flat, hard surface:

Ensure that the vehicle is in park mode if it is automatic, or in first gear if it is a manual. Engage the parking brake to prevent the vehicle from moving.

Locate and remove the old fuel tank cap:

Open the fuel door to access the fuel tank cap. Check the cap for any exterior damage, such as cracks or a missing gasket (the rubber seal at the top of the cap). If the cap is damaged, proceed to remove it by unscrewing it in a counter-clockwise direction.

Clean the fuel filler neck:

Use a clean cloth or paper towel to wipe down the threads on the fuel filler neck, removing any dirt or debris.

Install the new fuel tank cap:

• Pressure Release & Quick-On Locking Gas Caps: Insert the new cap into the opening of the fuel tank and rotate it clockwise until you hear three distinct clicks. Do not insert the key into the cap during installation. Test the cap by trying to turn it to the left; it should not move if properly installed.
• Metal Push-On Locking Gas Cap: Push the cap directly into the filler neck of the fuel tank until you hear a click. Do not turn the cap or insert the key during installation. Test the cap by wiggling it slightly; it should not move much or lift away.
• Standard Gas Cap: Insert the cap into the opening of the fuel tank and rotate it clockwise until it feels secure and clicks closed.

Test the new fuel tank cap:

Take the vehicle for a test drive, going over different terrain and allowing the fuel to slosh around inside the tank. Monitor the dashboard for any warning lights, such as the engine light, which may indicate an issue with the fuel system or fuel filler cap.

It is important to note that fuel leakage can be dangerous due to the flammability of fuel vapors. Always exercise caution and refer to your vehicle's manual for specific instructions related to your 2006 Ford Expedition.

Frequently asked questions