Ameer Randolph
Replacing the fuel pump in a Ford Bronco is a straightforward job. To do this, you need to access the plastic body by removing the float, disconnecting the cables, and pulling the metal cap apart from the plastic body. You then need to undo the plastic clips all around the body to release it. Once the body is open, you can replace the pump and reassemble the fuel pump assembly.
| Characteristics | Values |
|---|---|
| Accessing the plastic body | Remove the float, disconnect the 2 cables remaining (pump feed), pull the metal cap apart from the plastic body, remove the plastic body cap |
| Replacing the pump | Undo the plastic clips all around the body to release it, replace the pump, reassemble the fuel pump assembly |
| Removing the tank | Lift the bronco so you can pull the tank out, clean the area to avoid dirt/debris falling into the tank |
| Removing the locking ring | Slide the locking ring to remove it, use a screwdriver and hammer/mallet but avoid making sparks |
| Replacing the rubber O-ring | Maneuver the fuel pump to get the float and sock out, be careful not to drop the sock in the tank |
| Disconnecting the wires | Cut the wires off the fuel pump, splice the new fuel pump wires onto the sender unit using the provided crimps |
| Removing the pump from the sender unit | Undo the 2 bolts, remove the 2 nuts |
| Cleaning the tank | Wash the inside with solvent and fuel until there is no more dirt/rust coming out |
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What You'll Learn
Removing the float
To remove the float, you will need to disconnect the red cable and take the float off. There are three bolts holding the float in place, so you will need to undo these. Be very careful when doing this, and make sure you check the condition of every cable. It's a good idea to take pictures on your smartphone as you go, so you can refer back to them when it comes to reassembling the fuel pump.
Once the float is disconnected, you will need to manoeuvre the fuel pump to get the float and sock out. Be careful not to drop the sock in the tank.
Next, disconnect the two remaining cables (the pump feed) and pull the metal cap apart from the plastic body. The two pipes coming inside the plastic body will come out with the cap.
Finally, remove the plastic body cap and replace the pump and the in-tank filter. You can now reassemble the fuel pump assembly.
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Disconnecting the cables
First, make sure you have access to the plastic body by removing the float and disconnecting the two remaining cables (pump feed). Be careful when handling these cables, as they are essential for the proper functioning of the fuel pump. Next, you'll need to pull the metal cap apart from the plastic body. This action will cause the two pipes inside the plastic body to come out as well. It's important to be gentle during this step to avoid damaging any components.
Once the metal cap is removed, you can focus on the plastic body cap. Undo the plastic clips around the body to release it. This step requires patience and precision. Use a small screwdriver if needed, but be careful not to break any of the tabs or clips. With the body open, you'll have access to the fuel pump and the cables that need to be disconnected.
At this point, you'll need to disconnect the red cable and any other cables that are connected to the fuel pump. Take your time and be meticulous, checking the condition of each cable. It's a good idea to take pictures with your smartphone to guide you during the reassembly process. Make sure you know how everything is connected before proceeding.
Finally, you can remove the fuel pump itself. This step may vary depending on the model of your Bronco, but it typically involves undoing bolts and cutting or splicing wires. Always refer to the instructions provided with your specific fuel pump for the most accurate guidance.
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Pulling the metal cap apart from the plastic body
To replace the fuel pump in a Ford Bronco, you need to access the plastic body. To do this, you must first remove the float and disconnect the two remaining cables (pump feed). Then, you can pull the metal cap apart from the plastic body. The two pipes coming inside the plastic body will come out when you do this.
It's important to be careful and methodical when working on your Bronco's fuel pump. Take your time and make sure you understand how everything is connected. It can be helpful to take pictures with your smartphone as you go so that you can refer back to them during reassembly. This will ensure that you put everything back together correctly and avoid any potential issues.
Once you have replaced the pump and filter, you can reassemble the fuel pump assembly, following the same steps in reverse. Make sure that all connections are secure and that there are no leaks before starting your Bronco.
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Replacing the pump and in-tank filter
To replace the pump and in-tank filter, you first need to access the plastic body. Remove the float and disconnect the two cables remaining (pump feed). Pull the metal cap apart from the plastic body and remove the plastic body cap. You can then replace the pump and the in-tank filter.
To remove the plastic body cap, undo the plastic clips all around the body to release it. This requires patience, not brute strength, so be careful not to break any of the tabs or clips. A small screwdriver might be useful here.
Once the body is open, replace the pump and place everything inside back in the same way it was. This should be a pretty straightforward job.
Before starting, make sure you clean the area. You don't want dirt or debris falling into your tank.
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Reassembling the fuel pump assembly
To reassemble the fuel pump assembly, you need to reverse the steps you took to remove the old pump. First, you need to access the plastic body. Remove the float and disconnect the two cables remaining (pump feed). Pull the metal cap apart from the plastic body, and then replace the pump and the in-tank filter. Make sure you clean the area so that no dirt or debris falls into the tank. Slide the locking ring so you can remove it, and then replace the rubber O-ring that comes with the fuel pump. Be careful not to make any sparks. Maneuver the fuel pump to get the float and sock out, being careful not to drop the sock in the tank.
Once the body is open, replace the pump and place everything inside back in the same way it was. This should be a pretty straightforward job. Make sure you don't break any of the tabs or clips (a small screwdriver might come in handy here).
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Frequently asked questions
You need to access the plastic body in order to replace the old pump. To do so, remove the float, disconnect the 2 cables remaining (pump feed), pull the metal cap apart from the plastic body, and remove the plastic body cap.
Undo the plastic clips all around the body to release it. This requires some patience, not brute strength, so be careful not to break any of the tabs/clips. A small screwdriver might come in handy here.
Once the body is open, replace the pump and place everything inside back in the same way it was. This should be a pretty straightforward job.
With the pump assembly outside the tank, disconnect the red cable and take the float off. Be very careful of how everything is connected, check the condition of every cable, and take some pictures to guide yourself with the re-assembly.
Make sure you clean the area. You do not want dirt or debris falling into your tank. Also, be careful not to drop the sock in the tank when you are maneuvering the fuel pump to get the float and sock out.
