Replacing Fuel Pump In 2002 Ford Explorer: Step-By-Step Guide

Replacing the fuel pump in a 2002 Ford Explorer can be a complex process. The fuel pump is responsible for delivering fuel from the tank to the engine, and issues with the pump can cause engine stalling, loss of power, or even prevent the car from starting. While it is possible to replace the fuel pump yourself, it is recommended that you seek a professional mechanic to avoid the risk of fire. The cost of replacing a fuel pump can range from $267 to $1978, depending on labour and parts.

The process of replacing the fuel pump involves disconnecting the battery, draining the fuel tank, and removing the fuel pump through an access panel. It is important to take precautions and ensure that you have the correct tools and knowledge before attempting to replace the fuel pump yourself.

Disconnect the negative battery terminal

Disconnecting the battery is an important step when replacing the fuel pump in a 2002 Ford Explorer. Here is a detailed, step-by-step guide on how to safely disconnect the negative battery terminal:

Safety First

Before you begin, ensure that you are wearing the appropriate safety gear, including safety glasses and gloves. Remove any jewellery that you are wearing. These precautions will help protect you from electrical hazards and sparks.

Locate the Battery

The battery is typically located under the hood of your Ford Explorer. However, for some vehicles, it may be in the trunk. If you are unsure, always refer to your owner's manual to determine the correct location.

Identify the Negative Terminal

The negative battery terminal is usually identified by a "-" symbol and a black cable connected to it. In contrast, the positive terminal is marked with a "+" symbol and a red cable. The negative terminal is also known as the ground strap or cable and is directly connected to the vehicle's engine, body, and chassis.

Disconnect the Negative Terminal

Using a wrench, loosen the nut on the negative terminal. Be careful not to let the wrench touch the positive terminal or any other metal parts during this process. Once the nut is loose, remove the cable from the battery post. Ensure that the cable is kept away from the terminals to avoid accidental contact.

Secure the Cable

After removing the cable, ensure that it is securely tucked away and cannot come into contact with the battery terminals. This step is crucial to prevent short circuits and accidental electrical discharges.

Positive Terminal (Optional)

If you need to remove the positive terminal as well, follow similar steps. Loosen the nut with a wrench and remove the cable. However, before removing it, wrap the terminal with a cloth or cover it with a plastic cup to prevent accidental contact with the battery or any metal parts of the engine.

Remember, it is essential always to disconnect the negative terminal first. Removing the positive terminal first can create a situation where a tool or the engine/body of the car comes into contact with the positive terminal, potentially causing sparks, shorts, or other electrical issues.

Jack up the rear of the car

Jacking up the rear of your 2002 Ford Explorer can be dangerous if done incorrectly, so it's important to take the proper precautions and follow the correct procedure. Here's a detailed guide on how to do it safely and effectively:

First, locate the jack kit and jack points on your Explorer. The jack kit typically includes the jack, a jack handle, and a lug nut wrench. You can refer to your owner's manual or watch instructional videos online to identify the jack location and jack points. It is crucial to use the designated jack points to avoid damaging your vehicle.

Before you begin, place the vehicle on a level surface and engage the parking brake to prevent accidental movement. Once you have identified the jack points, position the jack securely underneath the vehicle, following the instructions in your manual. Make sure to use jack stands for added safety. Jack stands provide stability and reduce the risk of the vehicle accidentally falling or collapsing.

Now, you can start the process of jacking up the rear of the car. Here's a step-by-step guide:

• Place a piece of plywood or a similar sturdy material under the differential of the rear axle. This will help distribute the weight evenly and prevent damage to the differential.
• Position the jack under the rear differential, ensuring it is centred and stable.
• Engage the jack by pumping the handle or operating the mechanism according to the instructions. Do this slowly and steadily to lift the rear of the vehicle.
• Once the rear of the vehicle is raised, place jack stands near the rear wheels for added support.
• Lower the vehicle slightly so that it rests on the jack stands. Ensure that the vehicle is secure and stable by giving it a gentle wiggle.
• Now, you can crawl under the vehicle to access the fuel tank and perform the necessary repairs or maintenance.

Remember to work with a helper whenever possible, and never get under the vehicle while it is solely supported by the jack. Always use jack stands and follow safe jacking practices to minimise the risk of injury.

Release the fuel system pressure and drain the tank

To release the fuel system pressure and drain the tank of a 2002 Ford Explorer, follow these steps:

Firstly, ensure the vehicle is in neutral and positioned on a hoist. It is important to take safety precautions when working with fuel systems, so refer to the safety warnings in the Ford Explorer service manual. Disconnect the battery ground cable. Be prepared to collect any escaping fluid by loosening the clamp and disconnecting the hose. Use suitable paper to absorb any fluid. Some fuel may remain in the fuel tank filler pipe, so carefully drain this into a suitable container. Insert the hose from the fuel storage tanker and siphon the fuel through the hose.

Now, to release the pressure, there are a few methods. One way is to pull the fuel pump fuse under the hood and crank the engine a few times. Alternatively, there is a cap and valve on the fuel rail on the passenger side towards the back. You can slowly press the centre pin of the valve to release the gasoline, but be sure to place a rag around it. This valve is similar to a tire valve. Another option is to unplug the switch under the passenger's side foot area, which is known as the "crash thingy". Then, crank the engine for a second to release the pressure.

Once the pressure is released, you can proceed to drain the tank. Remove the fuel tank skid plates with a socket wrench and use a jack to support the fuel tank. Take out the strap bolt for the fuel tank and then remove the fuel tank itself.

Remove the fuel tank skid plates

To remove the fuel tank skid plates from a 2002 Ford Explorer, you will need a socket wrench, a jack, and a fuel tank skid plate. Here is a step-by-step guide:

• Position your vehicle on a hoist and place it in neutral.
• Release the fuel system pressure and drain the tank.
• Using a socket wrench, remove the fuel tank skid plates.
• Support the fuel tank with a jack.
• Take out the strap bolt for the fuel tank using a socket wrench.
• Remove the fuel tank and disconnect the vapor tube fitting.

At this point, you can continue with the fuel pump replacement procedure. Remember to exercise caution when working with the fuel system and always refer to a professional mechanic if you are unsure about any steps or procedures.

Remove the fuel tank

To remove the fuel tank from a 2002 Ford Explorer, first, jack up the rear of the car and secure it on jack stands. Disconnect the negative battery terminal. Crawl under the car and loosen the spiral clamp holding the rubber fuel fill hose at the rear of the gas tank. Pull off the hose and remove the forward-leading hose from the electric valve. Set up a floor jack under the fuel tank with a piece of plywood between the jack and the fuel tank to prevent damage to the thin plastic tank. Gently jack up against the tank to transfer the weight of the tank from the mounting straps to the jack.

Remove the forward mounting strap using a 15mm deep socket. To remove the rear mounting strap, unbolt the drive shaft using a 12-point 12mm socket and move it about an inch away from the tank. This will require putting the transmission in park to remove the bolts. With the mounting straps removed, lower the jack until the rear end of the tank is on the ground. There are no mentions of any hoses that need to be unhooked as the tank is lowered, but it is noted that there are two electrical plugs and two hoses that must be removed to take out the fuel pump.

Frequently asked questions