Rajan Wilcox
Removing the fuel tank from a 1994 Ford Explorer is a complex process that requires careful attention to safety. It is important to relieve the fuel pressure and disconnect the fuel filter lines, filler hose, and vent lines before attempting to remove the tank. The electrical connector must also be unplugged, and the transmission crossmember loosened. It is also recommended to only have a gallon or two of gas in the tank before starting the job.
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What You'll Learn
Disconnect fuel filter lines, filler hose, and vent lines
To disconnect the fuel filter lines, filler hose, and vent lines of a 1994 Ford Explorer, follow these steps:
Firstly, ensure you have relieved the fuel pressure. Then, disconnect the fuel filter lines at the front end. Be sure to use the proper procedure when disconnecting the fittings, as they may be damaged otherwise. For example, if your model is equipped with a pressurized fuel system, the "Quick Connect" fittings must be used. To disconnect these, spread the two hairpin clip legs about 1/8 inch (3mm) each to disengage them from the fitting, then pull the clip outward, using only finger pressure. Do not use any tools.
Next, disconnect the filler hose at the rear. You will also need to disconnect a couple of vent lines at the rear. Be careful when removing the plastic fitting connectors. There is one on the rear that you need to press in to expand it to remove it from the tank. This can be seen through the right rear wheel well with the wheel removed, or it can be removed with the tank part-way down.
To access the fuel pump, it is necessary to remove the fuel tank. You will need to loosen the left side of the transmission crossmember, loosen the two centre tranny nuts, and remove the right-side bolts. Then, lower the tank using a jack about three inches. Two straps hold the tank in place, so lower it carefully. As the tank is coming down, you will see an electrical connector that needs to be unplugged when the tank is part-way down.
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Remove plastic fitting connectors
To remove plastic fitting connectors from a 1994 Ford Explorer, you will first need to disconnect some of the lines before dropping the tank. This includes the fuel filter lines at the front end, the filler hose, and the vent lines at the rear.
Be careful to properly remove the plastic fitting connectors. There is one on the rear that you need to press in to expand and remove from the tank. You can see this through the right rear wheel well with the wheel removed, or you can remove it with the tank part-way down.
To remove plastic pipe connectors, you will need to push up on the fitting to loosen the locking clip inside. Then, squeeze the sleeve while still pushing up to release the clip. This will allow you to remove the whole assembly.
Another method for removing plastic pipe connectors involves using a tool called a HepKey. This tool is designed to seamlessly release pipes in a push-fit system. Simply clip the HepKey around the pipe to depress the inner sleeve of the fitting, which will open the stainless steel grab ring and release the pipe.
When removing plastic fittings, it is important to use the proper procedure to avoid damage. For example, Quick Connect" fittings are used on models equipped with a pressurized fuel system, and these must be disconnected carefully. The fuel filter uses a "hairpin" clip retainer, which can be disengaged by spreading the two legs about 1/8 inch (3mm) each and then pulling the clip outward.
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Loosen transmission crossmember, tranny nuts, and right-side bolts
Loosening the transmission crossmember, tranny nuts, and right-side bolts is a crucial step in removing the fuel tank from a 1994 Ford Explorer. Here is a detailed, step-by-step guide on how to approach this task:
First, it is important to understand the components involved. The transmission crossmember is a structural element that supports the transmission system of your Ford Explorer. It is typically bolted to the frame of the vehicle, and it is responsible for holding the transmission in place. The "tranny nuts" refer to the nuts that secure the transmission crossmember to the frame, and the right-side bolts are likely the bolts that attach other components to the transmission crossmember or the vehicle's frame.
To begin the process, locate the transmission crossmember and identify the bolts and nuts that need to be loosened or removed. Place a jack under the transmission crossmember for support. Before loosening any bolts or nuts, ensure that you have a stable and secure workspace, and consider placing a jack or stand under the transmission for added stability.
Start by loosening the left side of the transmission crossmember. Use the appropriate-sized wrench or socket to loosen the nuts or bolts, being careful not to strip the threads. Depending on the condition of the nuts and bolts, you may need to apply penetrating oil or use an impact wrench to break them free. Once the left side is loosened, move on to the center tranny nuts. Again, use the correct tool to loosen these nuts without stripping the threads. If the nuts or bolts are severely rusted or damaged, you may need to use a grinder to smooth the bolt before attempting to loosen it further.
For the right-side bolts, follow a similar procedure as for the left side. Ensure that you have the correct size tool for the bolts and carefully loosen them. If the bolts are difficult to access, you may need to use a socket wrench with an extension. It is important to note that if any of the bolts or nuts are severely damaged or broken, you may need to drill them out as described in other sources. This involves drilling a small hole in the center of the bolt and using an air hammer to remove the remnants.
Once you have successfully loosened or removed the necessary transmission crossmember bolts and nuts, you can continue with the process of removing the fuel tank. Remember to refer to a trusted repair manual or seek advice from a qualified mechanic if you are unsure about any steps or procedures.
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Lower the tank with a jack
Lowering the fuel tank of a 1994 Ford Explorer with a jack is a delicate procedure that requires careful attention to detail. Here is a step-by-step guide to help you through the process:
Before you begin, it is essential to ensure your safety and the stability of the vehicle. Place the car on a flat, level surface and engage the parking brake. Additionally, remove the fuel filler cap to relieve any built-up pressure in the tank.
Now, locate the transmission crossmember and loosen the bolts on the left side. Next, loosen the two center transmission nuts, and finally, remove the bolts on the right side. This will allow you to lower the crossmember gently with a jack.
As you lower the tank, pay close attention to the electrical connector. When the tank is partway down, you will need to unplug this connector. Two straps hold the tank in place, so use a floor jack and a piece of plywood (around 18 inches square) to support the tank and distribute the weight evenly.
Once the tank is lowered, you will have better access to the fuel pump and sending unit for maintenance or replacement. Remember to exercise caution throughout the process, as dealing with fuel systems can be hazardous. Always refer to a qualified mechanic if you are unsure about any steps or procedures.
Some people have suggested cutting an access hole in the body of the vehicle to reach the pump, but this is a more invasive method that may not be necessary if you can successfully lower the tank with a jack.
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Disconnect electrical connector
To disconnect the electrical connector, you will first need to drop the tank a bit. You can do this by loosening the left side of the transmission crossmember, loosening the two centre tranny nuts, and removing the right-side bolts. Let the tank down about three inches using a jack.
Once the tank is partway down, you will be able to see the electrical connector. You will need to unplug it.
There are a few other lines that will also need to be disconnected before dropping the tank fully. These include the fuel filter lines at the front end, the filler hose, and a couple of vent lines at the rear.
If you are removing the fuel tank to access the fuel pump, you will also need to disconnect the spade connector and remove the two screws and fuel sending unit.
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Frequently asked questions
To remove the fuel tank from your 1994 Ford Explorer, you must first depressurise the fuel system and remove the fuel tank from the vehicle. You will then need to remove the fuel pump locking ring using a locking ring removal tool, followed by the fuel pump and bracket assembly.
You will need a locking ring removal tool, also known as a fuel tank lock ring wrench tool, to remove the fuel pump locking ring. You will also need a car jack to lift the tank and a short piece of 2x8 wood to hold it in place while you reattach the straps.
To remove the fuel lines, you will need to disconnect the "Quick Connect" fittings. These are found on models with a pressurised fuel system. Use finger pressure only and avoid any tools.
You will need to disconnect some lines before dropping the tank, including the fuel filter lines at the front end, the filler hose, and the vent lines at the rear. Be careful when removing the plastic fitting connectors, especially the one at the rear, which you need to press in to expand and remove.
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