Exploring Fuel Pump Replacement In 05 Explorers

Replacing the fuel pump in a 2005 Ford Explorer can be a complex task. Before you begin, it is important to determine the correct fuel pump for your vehicle, as the type of engine will influence the pump you need. Once you have the right pump, you will need to position your vehicle on a hoist and place it in neutral. From there, you can begin to release the fuel system pressure, drain the tank, and remove the fuel tank skid plates with a socket wrench. It is also important to note that you may need to clean or replace your fuel pump if your fuel tank is not empty but your engine is having trouble getting fuel.

Prepare your vehicle for servicing

Before you begin any work on your 2005 Ford Explorer, there are several important steps you should take to prepare your vehicle for servicing. These steps will help ensure your safety and make the fuel pump replacement process more efficient.

First and foremost, park your vehicle on a level surface and engage the parking brake. This will prevent the vehicle from moving during the repair process. Next, you should disconnect the battery to eliminate the risk of electrical shocks or short circuits. It is also crucial to work in a well-ventilated area to avoid inhaling fuel fumes, which can be dangerous. Wear protective gear, including gloves and eye protection, to shield yourself from fuel and debris. Additionally, keep a fire extinguisher nearby as a safety precaution in case of any sparks or ignition sources.

Now, you can proceed to locate the fuel pump. The fuel pump on your 2005 Ford Explorer is located inside the fuel tank. To access it, you will need to jack up the rear of the vehicle and place jack stands under the spring perches for support. Remove the rear wheel on the driver's side to expose the fuel tank. Identify the electrical connector for the fuel tank, which is located just over the rear axle on the inner frame rail. Disconnect this electrical connector by pushing in a clip to release it.

At this point, you should also ensure that the fuel tank is as empty as possible to reduce the risk of fuel spillage during the replacement process. With the engine running, pull the fuel pump relay to release pressure from the fuel line.

By following these steps, you will have safely prepared your 2005 Ford Explorer for servicing and will be ready to proceed with the fuel pump replacement. Remember to work cautiously and refer to repair manuals or seek expert advice if needed.

Release the fuel system pressure

To release the fuel system pressure on a 2005 Ford Explorer, follow these steps:

First, park your vehicle on a level surface and engage the parking brake. It is important to ensure your vehicle is secure and will not move during this process. Next, locate the fuel pump relay in the power distribution box under the hood. The power distribution box is usually located on the driver's side of the engine compartment, near the back firewall. The fuel pump relay is a blue, box-style relay, and its exact location can be found in your owner's manual. Once located, remove the fuel pump relay to release the pressure from the fuel line.

Alternatively, you can release the fuel system pressure by locating the Schrader valve on the fuel rail. The Schrader valve is similar to a tire valve and is found on the passenger side of the vehicle, towards the back. Place a rag around the valve before slowly pressing the centre pin to release the gasoline.

Another method to release the fuel system pressure is to unplug the inertia switch, also known as the "crash thingy," under the passenger's side foot area. After unplugging the switch, simply crank the engine for a few seconds to relieve the pressure.

Always exercise extreme caution when working on your fuel system and refer to your owner's manual for detailed instructions specific to your vehicle.

Drain the tank

To drain the fuel tank of a 2002-2005 Ford Explorer, you have several options:

Use the fuel pump

You can remove the fuel pump relay and hotwire it, or unplug the inertia switch and run battery power to the pump. Alternatively, you can jumper the power at the fuel pump relay to let the fuel pump do the work.

Disconnect the fuel line

You can disconnect the fuel line at the motor and use the tank pump to pump out the fuel. You can also remove the filler hose at the tank and put a hose to a hand pump in through the filler hose.

Siphoning

You can siphon the fuel through the filler neck. Cut a piece of clear 3/8" OD tubing at a 30-degree angle and fold the tip over. Insert a small funnel in the top of the filler neck to hold the splash-back guard open and allow the hose to be easily withdrawn.

Other methods

• Drive the car until you run out of gas.
• Use an electric drill-operated pump with a small-diameter hose.
• Cut an access hole through the body of the car to drain the tank.

Remove the fuel tank skid plates

To remove the fuel tank skid plate from your 2005 Ford Explorer, you'll need to gather the right tools and hardware, locate the mounting hardware, and then remove the bolts holding the skid plate in place. Here's a detailed guide to help you through the process:

Tools and Hardware:

Before you begin, make sure you have the necessary tools and hardware. For this task, you'll need:

• A 15mm socket
• A 6" extension
• A 3/8" ratchet
• A flashlight (optional)

Locating the Mounting Hardware:

The skid plate is held in place by several bolts and clips. To locate them, follow these steps:

• Locate the two easily visible squares and circles in the frame.
• Insert two of the four threaded clips that you purchased into these holes.
• Find your rear axle shaft and look just in front of it. You'll see another square with a circle. Insert the third clip here.
• If you have a fourth-generation Explorer, there's an additional clip location. Get underneath the car, go to the rear strap on the fuel tank, and look above the driveshaft. You'll find another square and circle where you can insert the last clip.

Removing the Skid Plate:

Once you've located and inserted the clips, you can proceed to remove the skid plate:

• Take one of the bolts, the bracket, and thread the bolt into place using your ratchet. Tighten it, but leave it loose enough to allow for adjustments.
• Go to the front strap of the fuel tank and look above it. You'll see an oval with a notch where the nut plate will be installed.
• Install the two nuts you have onto the inner bolts of the front tank strap.
• Now, lift the skid plate into place and tighten all the bolts with your ratchet.

Additional Tips:

• This process is similar for both third and fourth-generation Explorers, with minor variations.
• Some Explorers may have an optional fuel tank skid plate, while others may not have one at all.
• If you're having trouble locating the bolts or clips, consider using a flashlight to illuminate the underside of the vehicle.
• Always exercise caution when working underneath a vehicle, and ensure that the car is securely supported on jack stands.

By following these steps, you should be able to successfully remove the fuel tank skid plate from your 2005 Ford Explorer.

Use a jack to support the fuel tank

To replace the fuel pump in a 2005 Explorer, you'll need to use a jack to support the fuel tank. Here's a detailed guide on how to do this:

Begin by getting the tank as empty as possible. Then, with the engine running, pull the fuel pump relay to release pressure from the fuel line. Loosen the lug nuts on the driver's side (DS) rear wheel. Jack up the rear of the truck as high as possible and place safety stands under the spring perches. Next, jack up the front of the truck until the wheels are just off the ground and place it on safety stands as well.

Remove the DS rear wheel. The electrical connector/plug for the fuel tank is located just over the rear axle on the inner frame rail. Take it loose from the frame and unplug it by pushing in a clip to release it. Remove the two 17mm bolts from the front of the tank. It does not need to be supported at this stage.

Now, support the rear of the tank with a piece of wood on top of a floor jack. Remove the 13mm bolt from the centre tank strap. As you do this, the front of the tank will drop onto its mounting bracket. At this point, you can put a tie wrap through the innermost bolt hole to prevent the tank from sliding rearward. This will also allow you to move the tank without dropping it.

Pivot the tank towards the drive shaft to allow enough room to unhook the tank strap from the frame rail. It keys into the frame from the top. Begin lowering the rear of the tank until you can access and disconnect the following:

• Hose clamps that hold the fill and vent hoses to the rear of the tank
• The other electrical plug on top of the tank (release it by pushing a clip)
• The evap system hose (this has a light grey plastic clip that must be squeezed to release; be careful not to break it)

Once everything is disconnected, you can drop the front of the tank (cut the wire tie and slide it rearward). Now, remove the fuel pump assembly by taking out the six 8mm bolts and carefully finagling the assembly out of the tank. Place the assembly on top of the leaf spring to work on it without having to disconnect the fuel line.

At this stage, you can drag the fuel tank out of the way and check the sump for any dirt, cleaning as necessary. You can also clean and apply a little Vaseline to the gasket surface to aid sealing during reassembly.

To remove the fuel pump from the assembly, first, remove the small screw/bolt that holds the clamp around the pump. Then, remove the hose clamps that hold the pump to the regulator and unplug the electrical connector from the pump. The pump will now slide out from a "U" shaped recess on the bottom of the assembly.

Finally, to reinstall the new pump, simply follow these steps in reverse.

Frequently asked questions