Exploring Fuel Pump Replacement In A 2001 Ford Explorer

If you're experiencing issues with your 2001 Ford Explorer's fuel pump, you may need to replace it. The fuel pump is located inside your fuel tank and ensures that pressurised gasoline flows to the engine to power the vehicle. While fuel pumps typically last for the lifespan of the car, they can occasionally fail. Signs of failure include a car that won't start, a stalled engine, or a slowly starving fuel flow causing the check engine light to turn on. In some cases, you may hear a whirring sound coming from the fuel tank, indicating that the fuel pump is about to fail.

To replace the fuel pump, a mechanic will need to access the failed pump through the top of the fuel tank via an access panel in the passenger compartment or by removing the tank from the vehicle. This is a moderately complicated job that is typically performed at a dealership's service department. However, with the right tools and knowledge, it is possible to replace the fuel pump yourself.

Removing the spare wheel

First, safely raise your Ford Explorer and place it on jack stands, ensuring it is as high as possible. The jack stands should be positioned under the frame, just before the forward leaf spring perches, so that the axle drops slightly and provides more space to access the two lines at the rear of the tank.

Next, remove the two filler hoses at the rear of the tank. Loosen the hose clamps and work them off. Now, support the rear of the tank with a jack. There will be a plastic strap in the middle of the tank with a long bolt over the driveshaft, bolted to the frame. Use a wobble and long extension to remove this bolt. If needed, you can unbolt the driveshaft from the rear axle to gain more clearance.

At this point, you may want to remove the driver's side rear wheel to gain better access to the connections. Now, carefully lower the tank a little, ensuring not to drop it all the way down as this may cause the plastic EVAP hose to break. Remove the green EVAP line connector by squeezing the two tabs and pulling it off.

With the above steps completed, you have successfully removed the spare wheel and are ready to move on to the next steps in replacing the fuel pump.

Disconnecting the filler hoses

Firstly, locate the filler hoses at the rear of the fuel tank. There should be two of them. Before you begin, make sure you have the necessary tools, including a 13mm and a 16mm wrench or socket. Loosen the hose clamps securing the filler hoses in place. You may need to wiggle or work the hoses off gently. Be careful not to damage the hoses or the surrounding components. Once the hoses are loose, carefully remove them, ensuring that they do not fall or put any strain on the fuel lines.

If you have an assistant, it is helpful to have them support the fuel tank with a jack at this point. Place the jack under the rear of the tank to provide stability. Now, locate the plastic strap in the middle of the tank. This strap is secured by a long 13mm bolt that goes over the driveshaft and is bolted to the frame. Using a wobble and long extension, remove this bolt. If needed, you can gain more clearance by unbolting the driveshaft from the rear axle. This step may require a 12-point 12mm deep socket.

For the next step, you may want to remove the driver's side rear wheel to access the connections more easily. Lower the tank slightly, being cautious not to drop it all the way down, as this could cause the plastic EVAP hose to break. Remove the green EVAP line connector by squeezing the two tabs and pulling it off. Be gentle, as you don't want to damage the connector or the surrounding components. With the EVAP line disconnected, you can now disconnect the electrical connector to the fuel pump.

If you can reach them, remove the quick disconnects for the fuel lines. If not, you can carefully lower the tank a little more, taking care not to put any tension on the fuel lines. Be prepared for a significant amount of fuel to come out of the lines, so have some rags or a suitable container ready to catch the spillage. Once the fuel lines are disconnected, lift the tank back up to its original position to relieve the strain on the front tank bolts.

Now, you can proceed to remove the front tank bolts. With the tank supported, carefully lower it as far as it will go. You may need to slide it off the jack to gain enough clearance. Depending on the amount of fuel in the tank, you may need an assistant to help support the front of the tank during this process. Slide the tank towards the passenger side to free it from the strap. Then, lift the strap out of the T-slot in the driver's side frame rail, and slide the tank and strap out from under the vehicle.

Disconnecting the electrical connector

First, locate the electrical connector. It is usually attached to the fuel pump, which is inside the fuel tank. To access the fuel tank, you will need to raise your vehicle and place it on jack stands. Make sure the vehicle is as high as possible to provide ample workspace.

Once you have located the electrical connector, the next step is to carefully disconnect it. Before doing so, it is important to have rags or towels nearby, as there will be fuel spillage. You may also want to wear gloves and protective eyewear to shield your hands and eyes from any fuel splashes.

Now, carefully disconnect the electrical connector from the fuel pump. This step requires a bit of force, but be gentle to avoid damaging the connector or any surrounding components.

With the electrical connector disconnected, you can now focus on removing the fuel pump itself. This process involves additional steps, such as removing bolts and hoses, and it is important to have a second pair of hands to assist with this process.

Ensure you keep track of the order in which you remove components to make reinstallation easier. Additionally, be cautious when handling fuel lines to avoid putting any tension on them, as this could lead to leaks.

By following these steps, you will successfully disconnect the electrical connector and be well on your way to replacing the fuel pump in your 2001 Ford Explorer.

Removing the fuel tank

To remove the fuel tank on a 2001 Ford Explorer, you will need a long 16mm wrench for the front two bolts on the gas tank, a short 13mm, 8mm, and 7mm wrench, quick disconnect tools in assorted sizes, a long extension, a wobble, a jack, and a lot of patience. A second pair of hands can also be helpful.

Begin by lifting the Explorer and placing it on jack stands as high as it will go so that the tank can slide out. Put the stands under the frame just before the forward leaf spring perches so that the axle will drop a little bit, making it easier to access the two lines at the rear of the tank.

Next, remove the spare tire and the two filler hoses going to the rear of the tank. Loosen the hose clamps and work them off. Put your jack under the rear of the tank to support it. Towards the middle of the tank, there will be a plastic strap with a long 13mm bolt that is over the top of the driveshaft bolted to the frame. Use the wobble and long extension to remove it. If you want, you can unbolt the driveshaft from the rear axle to get more clearance. You will need a 12 point 12mm deep socket for this.

Now, drop the tank a little bit so you can reach the plastic evap line. Do not drop it all the way, as the plastic EVAP hose will break if stretched too far. Remove the green evap line connector by squeezing the two tabs and pulling it off. Disconnect the electrical connector to the pump. If you can reach the quick disconnects for the fuel lines, remove them now. If not, you can drop the tank a little more, but be careful not to put any tension on the fuel lines. There will be a lot of fuel coming out of the lines, so keep some rags handy.

Lift the tank back up to its original position to take the strain off the two bolts on the front of the tank, and remove them. Now, drop the tank as far as it will go—you may need to slide it off the jack to get enough clearance. Depending on how much fuel is in the tank, you may need a second pair of hands to support the front of the tank.

Finally, slide the tank off the jack if you haven't already, and move it to the passenger side to get it off the strap. Then, lift the strap out of the T-slot in the driver's side frame rail and slide it and the tank out from under the Explorer.

Replacing the fuel pump

The fuel pump in a 1995-2001 Ford Explorer is located inside the fuel tank and can be accessed either through an access panel in the passenger compartment or by removing the tank from the vehicle. Here is a step-by-step guide on how to replace the fuel pump:

Step 1: Prepare the Vehicle

• Park the vehicle on a level surface and engage the parking brake.
• Make sure the engine is cool before starting work.
• Disconnect the negative battery terminal to prevent any accidental electrical shorts.
• Jack up the rear of the vehicle and place jack stands under the frame for support.
• Remove the rear wheels for easier access to the fuel tank.

Step 2: Remove the Fuel Tank

• Locate the fuel tank and identify the fuel lines, hoses, and electrical connections.
• Place a drain pan or container under the fuel lines to catch any spilled fuel.
• Disconnect the fuel lines and hoses from the fuel tank using appropriate tools.
• Loosen the fuel tank straps or mounting bolts and carefully lower the tank down.

Step 3: Remove the Old Fuel Pump

• Once the fuel tank is accessible, remove the fuel pump sending unit or module assembly. This may require removing additional bolts or screws.
• Carefully remove the old fuel pump from the sending unit or module assembly. Take note of the fuel line routing and any electrical connections.

Step 4: Install the New Fuel Pump

• Obtain a new fuel pump that is compatible with your Ford Explorer.
• Install the new fuel pump into the sending unit or module assembly, ensuring that the fuel lines and electrical connections are properly routed.
• Secure the fuel pump in place using the appropriate screws or bolts.

Step 5: Reinstall the Fuel Tank and Connectors

• Carefully lift the fuel tank back into position and secure it with the straps or mounting bolts.
• Reconnect the fuel lines and hoses to the fuel tank, ensuring that all connections are tight and secure.
• Reattach any other components that were removed during the process, such as the spare tire or rear wheels.

Step 6: Final Checks

• Reconnect the negative battery terminal.
• Check for any fuel leaks around the tank and fuel lines.
• Start the engine and check for any unusual noises or warnings.
• Test drive the vehicle to ensure that the new fuel pump is functioning properly.

Frequently asked questions