Replacing Bronco Fuel Pumps: A Step-By-Step Guide

Replacing the fuel pump on a Ford Bronco can be a challenging task, but with the right tools and precautions, it is certainly achievable. The process involves siphoning the fuel, lifting the vehicle, removing the fuel tank, disconnecting the fuel lines and electrical connectors, and installing a new fuel pump. The fuel pump is located inside the fuel tank, so it is important to take precautions to avoid sparks and fires. It is also recommended to replace the fuel filter and check the fuel lines and wiring while the tank is out. The cost of replacing a fuel pump can vary depending on the vehicle and the location, but it typically ranges from $1,471 to $1,582.

Disconnect the battery and siphon the fuel from the tank

Disconnecting the battery is the first step in replacing the fuel pump of a Ford Bronco. This is done to reduce the chance of a fire. Siphoning the fuel from the tank is also important because a full tank weighs close to 300 lbs, while an empty tank weighs about 25 lbs. This makes it easier to remove the tank.

To siphon the fuel, you can use a fuel siphon pump or any effective means to retrieve the fuel. You don't want to handle the extra weight of a full tank. You will also need a fuel container to store the old fuel. It is usually recommended to refill the tank with fresh fuel as the particles in the old fuel might hurt the new pump.

After siphoning the fuel, you can then lift the Bronco to get easier access to the tank. You can use a jack or any other means to safely lift the Bronco and lower the tank.

Once the tank is supported, the next step is to remove the tank straps, tank shield, and filler neck. The filler neck can be removed by loosening the clamp joining the rubber hose to the filler neck and then removing the bolts holding the filler neck in place.

With the filler neck removed, you can then start to remove the tank shield. The tank shield is held in place by bolts and nuts. You can use a combination wrench to turn the bolt while using a socket wrench to loosen the nut. This will make it easier to remove the nuts/bolts without stripping them.

After removing the tank shield, you can then start to lower the tank. Make sure to do this slowly and carefully to avoid putting any tension on the fuel lines or the pump plug.

Now that the tank is lowered, you can start to disconnect the fuel lines and remove the tank from under the Bronco. With the tank removed, you can open it and retrieve the fuel pump assembly. This will allow you to replace the fuel pump and pick-up screen.

Overall, disconnecting the battery and siphoning the fuel from the tank are important steps in replacing the fuel pump of a Ford Bronco. These steps help to ensure a safe and efficient replacement process.

Disconnect electrical connectors and hoses from the fuel pump

Disconnecting the electrical connectors and hoses from the fuel pump is a crucial step in replacing the fuel pump in a Bronco. Here is a detailed guide on how to do this:

Before beginning any work, it is important to clean the area underneath the vehicle to ensure that debris does not fall into the fuel tank during the replacement process. It is also recommended to have the vehicle towed to a safe location if it is not running due to a faulty fuel pump. Once the vehicle is secured, wear eye protection and disconnect the battery to reduce the risk of fire.

To disconnect the electrical connectors and hoses from the fuel pump, follow these steps:

• Disconnect the electrical connector: Locate the electrical connector attached to the fuel pump. This is usually a plug-and-socket connection. Gently pull the connector apart, taking care not to damage the wires. Set the connector aside, ensuring it is covered to prevent dirt or debris from entering.
• Disconnect metal and rubber hoses: Identify all metal and rubber hoses connected to the fuel pump. These hoses carry fuel and must be carefully disconnected to avoid spills. Use a fuel line disconnect tool, available at most auto parts stores, to detach the hoses. Gently slide the correct size tool into the hose connection, press in, and then pull the hose back. This may require some effort, but it will help to separate the hose from the fuel pump safely.
• Cover and tuck hoses: Once all the hoses are disconnected, cover the openings with tape or plastic to prevent dirt or debris from entering. Tuck the hoses out of the way to ensure they do not interfere with the rest of the fuel pump replacement process.
• Remove the filler neck: Don't forget to disconnect the fuel tank from the filler neck. Loosen the clamp that holds the rubber hose to the filler neck, and then remove the bolts holding the filler neck in place. This will make it easier to access the fuel tank and pump.

By following these steps, you will safely disconnect the electrical connectors and hoses from the fuel pump, allowing you to proceed with the rest of the fuel pump replacement procedure for your Bronco. Remember to work carefully and consult a mechanic or a professional if you are unsure about any steps.

Remove the filler neck, skid plate and tank straps

To remove the filler neck, skid plate, and tank straps, follow these steps:

Firstly, disconnect the filler hose by loosening the clamp next to the tank. This will make re-attaching everything back much easier. There are three 6mm bolts holding the filler neck in place, so remove these with a socket wrench.

Next, remove the tank straps. There will be two bolts/nuts holding each strap in place, so remove these.

Now, remove the skid plate. There are eight bolts/nuts in total holding the skid plate in place, four at the front and four at the rear. Use a combination wrench to turn the bolt while using a socket wrench to loosen the nut. The gas tank will not be supported once these bolts are removed, so ensure it is properly supported with a jack.

With the skid plate removed, you can now lower the tank. Ensure you have siphoned as much fuel as possible beforehand to reduce the weight.

Lift the tank and slide it out

To replace the fuel pump in a Ford Bronco, you'll need to lift and slide out the gas tank. Here's a detailed guide on how to do this:

First, make sure you have the necessary tools and safety equipment. This includes eye protection, gloves, and a fire extinguisher, as well as a fuel siphon pump, jack stands, a jack, wrenches, and screwdrivers. It's also recommended to have the fuel tank as empty as possible to minimise weight.

Begin by siphoning the fuel from the tank. Lift the Bronco to provide easier access to the tank; a lift of around 3 inches should be sufficient. Support the fuel tank with a jack, ensuring it is centred properly.

Next, you'll need to remove the tank straps and the tank shield. The tank shield is held in place by 8 bolts and nuts; once these are removed, the tank will be unsupported, so ensure it is securely held by the jack.

Disconnect the fuel lines and the electrical connector from the tank. Be sure to cover the disconnected lines to prevent dirt from entering. Now, you can lift the tank and slide it out from under the vehicle.

It is important to work carefully and avoid creating any sparks, as this could cause a fire. Once the tank is out, you can open it and retrieve the fuel pump assembly for replacement.

Reinstallation is the reverse of the removal process. Be sure to clean the tank and the surrounding area before reinstalling, and check for any signs of rust or leaks.

This process should help you successfully lift and slide out the gas tank on your Ford Bronco, allowing you to access and replace the fuel pump.

Remove the locking ring and old fuel pump

To remove the locking ring and old fuel pump from your Bronco, follow these steps:

Firstly, ensure you have the correct tools for the job. You will need a screwdriver, a hammer/mallet, and a brass punch. It is also recommended to have a fuel pump line disconnection tool, which can be purchased from a local auto parts store.

Next, disconnect the electrical connector and all metal/rubber hoses going to the fuel pump. Cover the disconnected parts to keep them clean and move them out of the way.

Now, disconnect the fuel pump lines. Use the correct size of the fuel pump line disconnection tool and slide it in, then press in and pull the fuel line back. It may take some effort to do this.

At this point, you can undo the straps to make it easier to move the tank around. Remember to also undo the filler neck.

Now, slide out the locking ring. Use a screwdriver and hammer/mallet to do this, but be gentle to avoid creating sparks. You can also use a brass punch or a wooden dowel.

Once the locking ring is removed, you can access the old fuel pump. Maneuver the fuel pump to get the float and sock out, being careful not to drop the sock into the tank.

Finally, undo the bolts and cut the wires connected to the fuel pump. Now, you can remove the old fuel pump from the sender unit.

Remember to work safely and take all necessary precautions when working with fuel systems, as there is a risk of fire.

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