Replacing Fuel Pump In '05 Mustang: Step-By-Step Guide

If your 2005 Mustang is experiencing hard starts, loss of power, or high rpm sputtering, it may be time to replace the fuel pump. The fuel pump is responsible for taking fuel from the gas tank and pumping it into the engine, so a faulty one will render your system useless. Luckily, replacing the fuel pump yourself is possible and can save you a decent amount of money. This is a complex process that involves siphoning your fuel tank, removing the rear seat cushion, and carefully disconnecting and reconnecting many parts, so be sure to follow a detailed guide and proceed with caution.

Empty the fuel tank

To replace the fuel pump in a 2005 Mustang, you will need to empty the fuel tank. This is because the fuel pump is located on top of the fuel tank, so to access it, you must drop the tank. Here is a step-by-step guide on how to empty the fuel tank:

Step 1: Obtain a siphon kit. This kit should include a hose and a manual pump. Stick the hose that comes with your siphon kit all the way down your fuel tank. When the hose reaches the bottom, connect the manual pump that came with the kit, and connect the other end of the hose to a container.

Step 2: Pump the fuel with your hand until there is no more fuel left in the tank. Be very careful during this step, as you are dealing with flammable fuel. Make sure you are in a well-ventilated area and avoid any potential sources of ignition.

Step 3: Once the tank is empty, remove the hose from the tank and safely dispose of the fuel in the container. Do not smoke or create any sparks near the fuel, and make sure to store it in a safe and properly labelled container, away from heat, sparks, and flames.

Step 4: Now that the tank is empty, you can begin the process of dropping it to access the fuel pump. Raise the car and secure it with jack stands.

Step 5: Disconnect all the hoses and connectors attached to the tank. This includes the filler neck, the two hoses next to the filler neck, the electrical connector on the back of the tank, the hoses on the driver's side, and the fuel filter's hoses.

Step 6: With all the connections to the tank disconnected, you can now begin to drop the tank. Place a jack underneath it and raise it until it touches the tank.

Step 7: The fuel tank is held in place by two brackets, each secured with a bolt on either side, for a total of four bolts. Remove these bolts to release the brackets.

Step 8: Slowly lower the tank and pull it out of the vehicle. Be careful not to damage any surrounding components.

Now that the fuel tank has been successfully emptied and removed, you can proceed to replace the fuel pump. Remember to exercise extreme caution when handling fuel, and ensure you have adequate ventilation at all times.

Raise the car

To replace the fuel pump of a 2005 Mustang, you will need to raise the car and secure it with jack stands. Here are some detailed, step-by-step instructions on how to do this safely and effectively:

Park your car on a flat, level surface:

Before you start, make sure you have a safe and spacious work area. Find a flat, level surface to park your car, such as a garage floor or a smooth driveway. This will ensure your car is stable and secure during the repair process.

Engage the parking brake:

Apply the parking brake firmly to prevent the car from rolling or moving unexpectedly while you are working underneath it. This is a critical step to ensure your safety and prevent accidents.

Place jack stands in the correct locations:

Position jack stands on a solid, level surface underneath the car. Refer to your vehicle's repair manual to identify the exact jacking points for your specific Mustang model. These jacking points are the reinforced structural areas designed to support the weight of the vehicle safely.

Lift the car with a jack:

Place a jack underneath the vehicle, following the instructions in your repair manual for the recommended lift point. Slowly raise the jack until it makes contact with the car's frame or lifting point. Continue jacking until the car is high enough off the ground to allow access to the fuel tank.

Secure the car with jack stands:

Once the car is raised to the desired height, carefully position the jack stands directly under the recommended jacking points. Lower the vehicle slowly onto the stands until they are firmly in place. Ensure that the car is stable and secure before proceeding.

Check the stability of the vehicle:

Before proceeding with any repairs, it is crucial to ensure the car is securely supported. Gently rock the vehicle slightly to confirm that it is stable and will not shift or move while you are working. Do not proceed if the car is not firmly in place.

Block the wheels:

As an additional safety measure, place wheel chocks or blocks behind the driving wheels (front wheels for a rear-wheel-drive car, and rear wheels for a front-wheel-drive car). This will provide extra security and prevent the car from rolling in either direction.

Now that the car is safely raised and secured, you can continue with the next steps of replacing the fuel pump. Remember to exercise caution and follow proper safety procedures throughout the entire process.

Disconnect hoses

Disconnecting the hoses from a fuel pump in a 2005 Mustang is a complex task and should be approached with caution. Before beginning, it is important to relieve the fuel system of any pressure. This can be done by locating the bleeder valve and attaching a fuel pressure bleeder system into a bucket or gas tank. Once the pressure is relieved, the negative battery terminal can be disconnected.

The next step is to remove the rear seat cushion and the rubber dust cover on the fuel pump. This will grant access to the fuel pump. Using a flat screwdriver, unlock the fuel pump connector by pushing the red tab back and pulling the connector off. Be cautious, as there may be some fuel trapped in the line. Next, remove the fuel line connector by pushing in the green tab and pulling back. Again, be prepared to catch any fuel that may be in the line.

Now, the locking ring must be spun counterclockwise to release the fuel pump from the gas tank. This can be done using a hammer and a brass punch. It is important to try and not damage the locking ring so that it can be reused.

Finally, the fuel pump can be carefully pulled up and out of the gas tank. Be cautious, as there may still be fuel on the fuel pump body.

Drop the fuel tank

Dropping the fuel tank is not necessary when replacing the fuel pump of a 2005 Mustang. However, if you would like to drop the fuel tank, here is a detailed guide on how to do so:

Firstly, locate the bleeder valve and attach a fuel pressure bleeder system into a bucket or gas tank to bleed off fuel pressure. Once the pressure is released, disconnect the negative (black) terminal of the battery. Be cautious when removing the bleeder valve, as fuel will start to spew out if the hose or bleeder is not connected.

Next, remove the rear seat cushion by unsnapping it from the bottom of the seat frame. Then, remove the rubber dust cover on the fuel pump by prying it up and setting it aside. Ensure that nothing falls in between the chassis and the gas tank.

Afterwards, unlock the fuel pump connector by pushing the red tab back and pulling the connector off. Then, remove the fuel line connector by pushing in the green tab and pulling back, being prepared to catch any fuel that is trapped in the line. Now, the locking ring has to be spun counterclockwise to release the fuel pump from the gas tank. Use a hammer and a brass punch to spin the locking ring. Try not to damage the locking ring so it can be reused.

Thoroughly clean the area around the fuel pump to ensure no dirt gets in the fuel tank. Now, carefully pull up on the fuel pump but do not remove it completely, as the crossover fuel line tube is still connected. This is removed in the same way as the fuel line on top of the fuel pump. The fuel pump is now ready to be removed. Be cautious as you take it out and be ready to catch any fuel that is on the fuel pump body.

Finally, with the fuel pump removed, the fuel tank will be exposed and ready to be dropped. It is recommended to have a friend help with holding the tank and use a jack with a piece of wood for support.

Replace the fuel pump

Step 1 – Prepare to replace the fuel pump

Before starting, ensure you have the right tools and parts for the job. You will need a replacement fuel pump, a fuel pressure bleeder, a brass punch and hammer, and a flat screwdriver. It is also recommended to wear protective clothing, including eye protection, as you will be working with fuel.

Step 2 – Bleed off fuel pressure

Start by locating the bleeder valve and attaching a fuel pressure bleeder system into a bucket or gas tank to bleed off fuel pressure. Once the pressure is released, you can disconnect the negative (black) terminal of the battery by loosening the 8mm nut. Be careful when removing the bleeder valve, as fuel will start to leak out.

Step 3 – Access the fuel pump

To access the fuel pump, you will need to remove the rear seat cushion by unsnapping it from the bottom of the seat frame. Remove any dust covers by prying them up and setting them aside. Be careful not to let anything fall in between the chassis and the gas tank.

Step 4 – Disconnect the fuel pump

Use a flat screwdriver to unlock the fuel pump connector by pushing the red tab back and pulling the connector off. Then, remove the fuel line connector by pushing the green tab and pulling it back. Be prepared to catch any fuel that is trapped in the line. Now, the locking ring must be spun counterclockwise to release the fuel pump from the gas tank. Use a hammer and brass punch to spin the locking ring. Try not to damage the locking ring so it can be reused.

Step 5 – Remove the fuel pump

Before removing the fuel pump, clean the area around it to ensure no dirt gets into the fuel tank. Carefully pull up on the fuel pump, but do not remove it completely, as the crossover fuel line tube is still connected. Remove this tube in the same way as the fuel line on top of the fuel pump. Now, carefully remove the fuel pump, being ready to catch any fuel that is on the fuel pump body.

Step 6 – Install the new fuel pump

Install the new fuel pump by reversing the previous steps. Ensure that the fuel lines "click" in and everything is seated properly. Reinstall your dust cover, seat cushion, and battery connection.

Step 7 – Test the new fuel pump

Once the new fuel pump is installed, inspect your tank seal and replace it if necessary. Clean all surfaces and seals that are being reused to ensure that no leaks occur. Start your car and observe if the fuel pump is functioning properly. You should notice improved power and reliability.

Frequently asked questions