Ameer Randolph
Removing the fuel tank from a 2002 Ford Explorer can be a challenging task. Before attempting to remove the fuel tank, it is recommended to drain the fuel or run the tank down to where only a gallon or two of gas remains. This can be done by disconnecting the filler neck hose and inserting a drain hose connected to a fuel caddy with a pump. Once the fuel tank is drained, the next step is to jack up the rear of the car and place a piece of plywood between the jack and the fuel tank to prevent damage. The fuel fill hose can then be loosened and removed, followed by disconnecting the electrical connectors and fuel lines. It is important to be cautious and follow the correct procedures to ensure a safe and successful fuel tank removal process.
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What You'll Learn
Disconnect the negative battery terminal
Disconnecting the negative battery terminal is an important first step when performing maintenance on your car. Here is a detailed guide on how to do this for a 2002 Ford Explorer:
First, locate the negative battery terminal. It is usually clearly marked, often with a black cover, and typically found on the left side of the battery.
Before disconnecting, ensure you have the necessary tools. You may need a wrench or socket set to loosen the terminal clamp. It is also recommended to have some dielectric grease on hand to prevent corrosion.
Once you are ready, start by loosening the negative battery cable clamp. You can do this by turning the clamp in a counter-clockwise direction with your wrench or socket. Be careful not to overtighten the connection, as this can damage the battery post.
After loosening the clamp, carefully remove the cable from the battery post. Pay attention to any corrosion or debris on the post and clean it off with a wire brush if necessary.
Now, apply a thin layer of dielectric grease to both the terminal and the connector. This will help prevent corrosion and ensure a better connection when you reassemble the battery.
Finally, carefully reconnect the negative battery cable, making sure it is secure and properly seated on the battery post. Tighten the clamp by turning it clockwise, but be careful not to over-tighten.
By following these steps, you can safely disconnect and reconnect the negative battery terminal on your 2002 Ford Explorer, allowing you to proceed with further maintenance or repairs.
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Jack up the rear of the car
Jacking up the rear of the car is an important step in removing the fuel tank of a 2002 Ford Explorer. Here is a detailed, step-by-step guide on how to do it:
Firstly, place a jack under the rear differential of the car. It is recommended to use a floor jack and place a plywood pad on top of the jack to protect the underside of the car. Gently jack up the rear of the car until it is lifted securely. It is important to ensure the car is stable by wiggling it slightly to make sure it is secure before proceeding.
Next, you will need to lower the fuel tank. Place a large piece of plywood or a similar flat, sturdy object, under the fuel tank to support it as it is lowered. Use a wheeled jack to carefully lower the tank. As the tank is lowered, be cautious of any hoses that may need to be unhooked. There are two electrical connectors that need to be unplugged as the tank descends.
Once the tank is lowered, you will need to remove the mounting straps. The forward mounting strap can be removed with a 15mm deep socket. The rear mounting strap is more difficult to access due to the angle of the bolt. To remove it, use a 12-point 12mm socket to unbolt the drive shaft and move it slightly away from the tank.
With the mounting straps removed, you can continue to lower the jack until the rear end of the tank is on the ground. It is important to be cautious and careful throughout this process to avoid any damage to the fuel tank or other components.
By following these steps, you will successfully jack up the rear of the car and be able to safely lower and remove the fuel tank of a 2002 Ford Explorer.
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Disconnect fuel filter lines
To disconnect the fuel filter lines on a 2002 Ford Explorer, you must first relieve the fuel system pressure. Do not use any tools for this step, as they may cause a deformity in the clip components, which may lead to fuel leaks.
Once the pressure is relieved, you can start disconnecting the fuel filter lines. The fuel filter lines on a 2002 Explorer are located near the gas tank. The inner line is the feed line, running from the fuel pump to the fuel filter, while the outer line is the return line, running from the fuel filter back to the gas tank.
There are a few methods you can use to disconnect the lines:
- Using a metal quick-disconnect tool: Push the line in while pushing the tool towards the retainer.
- Using a set of multi-coloured aluminium individual line disconnect tools: Leave the filter in its metal retaining clip, and once the line moves in, insert the 5/16 size and push on it with a pair of needle-nose pliers while pushing the line in.
- Using the scissors fuel disconnect tool.
- Rotating the filter to break any rust or corrosion.
If there is pressure in the line, it will be harder to disconnect. In this case, unplug the fuel relay in the power distribution box and try to start the vehicle. Some gas should enter the injectors, releasing the pressure.
It is important to note that you should not smoke or carry a lit flame near any fuel-related components, as highly flammable mixtures are always present.
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Remove filler hose
To remove the filler hose from a 2002 Ford Explorer, you will need to first relieve the fuel pressure.
The filler hose is connected to the fuel tank via a plastic fitting connector at the rear of the tank. This connector needs to be carefully removed by pressing it in to expand it and detaching it from the tank. It can be accessed through the right rear wheel well with the wheel removed, or it can be removed with the tank part way down.
There is also a quick-connect mechanism that needs to be released by pulling it out. Both the breather and the filler hose are released this way.
It is recommended to cut the wire ties that hold all the hoses together first, to make it easier to manipulate the filler hose.
Additionally, there are two bolts holding the lower section of the filler neck that should be removed. Knock off any rust and use a 13mm socket to remove them.
Finally, loosen the clamp that holds the lower tube of the filler neck to the fuel tank.
By following these steps, you should be able to successfully remove the filler hose from your 2002 Ford Explorer.
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Disconnect vent lines
To disconnect the vent lines on a 2002 Ford Explorer, you will need to first relieve the fuel pressure. You can do this by removing the filler neck hose and inserting a drain hose connected to a fuel caddy with a pump to pump the fuel out of the tank.
Once the fuel pressure has been relieved, you can disconnect 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 it to remove it from the tank. This can be seen through the right rear wheel well with the wheel removed or you can remove it with the tank part-way down.
It is also important to note that there are two straps holding the tank in place. You can let the tank down with a floor jack using an 18-inch square piece of plywood to spread out the load.
Additionally, as the tank is coming down, you will see the electrical connector that needs to be unplugged when the tank is part-way down.
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Frequently asked questions
First, disconnect the negative battery terminal. Jack up the rear of the car and place a piece of plywood between the jack and the fuel tank to prevent damage. Loosen the transmission crossmember and the two center tranny nuts, and remove the right-side bolts. Disconnect the fuel filter lines, filler hose, and vent lines. Be sure to relieve the fuel pressure.
You can drain the fuel by removing the filler neck hose and inserting a drain hose connected to a fuel caddy with a pump.
It is not necessary to drain the fuel before removing the tank, but it is easier to handle with less fuel in it.
You will need a floor jack, a piece of plywood, and a tool referred to as a Ford fuel line disconnect tool.
Be careful when removing the plastic fitting connectors. There is one on the rear that you need to press in to expand and remove it from the tank. As you lower the tank, look for any hoses that may need to be unhooked. There are also two electrical plugs that must be removed.
