Replacing The Fuel Pump In A 1996 Mustang: Step-By-Step Guide

Replacing the fuel pump on a 1996 Mustang is a complex task that requires a range of tools and safety precautions. Before starting, it's important to empty the fuel tank and raise the car securely. The process involves disconnecting hoses, electrical connectors, and bolts, before dropping the fuel tank and replacing the pump. It is crucial to be cautious when working with fuel and to take steps to prevent leaks and accidents.

Empty the fuel tank

Before beginning any work on your Mustang, make sure you are wearing appropriate safety gear, including eye protection and gloves. It is also important to never smoke when working with fuel and to avoid any open flames.

To access the fuel pump, you will need to drop the tank, so it is best to empty the tank completely before doing so. Start by sticking 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. Pump the fuel with your hand until the tank is empty. Remove the hose from the tank.

Although using your mouth to siphon the gas does work, it is extremely dangerous because the fumes you will be sucking can be deadly.

Now that the fuel tank is empty, you can move on to the next step of raising the car and securing it with jack stands.

Disconnect hoses and electrical connectors

Disconnecting the hoses and electrical connectors is a crucial step in replacing the fuel pump on a 1996 Mustang. Here is a detailed guide on how to do this:

First, make sure you have the necessary tools, including a line disconnect tool, a jack, jack stands, and a siphon kit. Place the Mustang on jack stands to raise it and secure it. It is important to ensure the car is stable and will not move during the process.

Next, locate the filler neck on the side of the fuel tank. This is the same side where you fill your fuel tank. Disconnect the filler neck and the two hoses next to it. Be cautious as fuel may spill during this step.

Now, move to the back of the car and unplug the electrical connector on the rear of the tank. Then, move to the driver's side of the car and disconnect the hoses on the opposite side of the filler neck. This includes the fuel filter's hoses, which can be disconnected using the line disconnect tool. Place the tool between the filter and the line, then push out to unclip it.

At this point, you have successfully disconnected the hoses and electrical connectors related to the fuel pump. You can now proceed to the next steps of dropping the fuel tank and replacing the fuel pump.

Safety is a priority when working with fuel systems. Ensure you are wearing appropriate protective gear, and take precautions to avoid any fuel spillage or leakage. Always refer to a professional mechanic if you are unsure about any steps in the process.

Drop the fuel tank

Dropping the fuel tank is a crucial step in accessing and replacing the fuel pump on a 1996 Mustang. Here is a detailed guide on how to safely lower the fuel tank:

Firstly, ensure you have emptied the fuel tank completely. Use a siphon kit to extract the fuel. Stick the hose into the fuel tank and connect the manual pump. Pump the fuel out into a container.

Now, raise the car and secure it with jack stands. Disconnect the filler neck and the two hoses next to it. These are located on the side where you fill your tank. Also, unplug the electrical connector at the back of the tank, towards the rear of the car.

Next, disconnect the hoses on the opposite side of the filler neck (driver's side). This includes detaching the fuel filter's hoses with a line disconnect tool. Place your jack under the fuel tank and raise it until it touches the tank. The tank is secured by two brackets, each held by one bolt on either side, making four bolts in total.

Remove these bolts and slowly lower the tank, pulling it out of the vehicle. Now, your fuel tank is ready to be dropped, and you can access the fuel pump for replacement.

When reinstalling the tank, ensure you wrap the brackets around it and tighten the bolts securely. Reconnect all the hoses and the electrical connector. Pour the fuel back into the tank, and your Mustang should be ready to start.

This process should take around 1-2 hours to complete and will require tools such as a jack, jack stands, a siphon kit, and a line disconnect tool.

Remove the fuel pump

To remove the fuel pump from a 1996 Mustang, you will first need to empty the fuel tank and drop it, as the fuel pump is located on top of the tank.

Step 1: Empty the Fuel Tank

Use a siphon kit to empty the fuel tank. Insert the hose that comes with the kit all the way down the fuel tank. When it reaches the bottom, connect the manual pump and the other end of the hose to a container. Pump the fuel out until the tank is empty.

Step 2: Raise the Car

Raise the car and secure it with jack stands.

Step 3: Remove Hoses Connected to the Tank

Disconnect the filler neck on the side of the tank where you fill it. Disconnect the two hoses next to the filler neck. Unplug the electrical connector on the back of the tank, towards the back of the car. Disconnect the hoses on the opposite side of the filler neck (driver's side). Use a line disconnect tool to disconnect the fuel filter's hoses connected to both ends.

Step 4: Drop the Fuel Tank

Place a jack under the fuel tank and raise it until it touches. The tank is held in place by two brackets, each secured with one bolt on each side (four bolts total). Remove the brackets and slowly lower the tank to pull it out of the vehicle.

Step 5: Remove the Fuel Pump

Use a line disconnect tool to remove the last hose connected directly to the fuel pump. Unbolt the six bolts holding the fuel pump in place. To remove the assembly, squeeze the clip holding the pump in place as you pull it out.

Now you can install a new fuel pump.

Install the new pump

Now that you have removed the old fuel pump, it's time to install the new one.

First, you will need to clean the engine block surface to ensure a good seal. Use a razor blade scraper to clean the surface, working away from the opening and moving from the centre outwards.

Next, you can apply a thin bead of gasket sealer to one side of the new gasket. You can also apply a thin film of gasket sealer to the pump face. Clean the face with a degreaser and lint-free cloth.

Now, you are ready to install the new pump. The top arm of the pump must be fitted under the cam in the engine block. Get the first bolt ready to hold the pump in place. When inserting the pump arm into the engine block opening, tip the arm downwards at a slight angle. When the pump is almost at the engine block, tilt the pump face back towards the parallel of the engine block pump face. This ensures the arm is under the cam before bolting into place.

With the pump in place, reattach the metal carb pipe to the output (female side) of the pump. Tighten the pipe into the mounting. Depending on the design of your pump, you may need to hold the mounting point nut with another spanner to avoid breaking the spot weld on the pump.

Now, attach the input line of the fuel pipe to the male part of the fuel filter. Use a 'lemon' clip or a single ear clip with the correct tool to make it look neater. There will be a flow arrow for the direction of the fuel on the filter, so make sure you get the flow direction correct, pointing to the fuel pump. You can also use a jubilee clip to attach the pipework if you prefer. Make sure the rubber fuel pipe is not kinked and forms as straight a route as possible to the fuel pump. Place the tubing to the fuel pump and secure it in place with a clip or jubilee clip.

You can now fill the filter with fuel so it's ready and primed. Or, you can start with the filter empty, so any fuel you see in the filter has been pulled in by the pump itself when being cranked over without starting the engine.

When connecting back up to the fuel line coming from the inner fender, undo the clamp previously put in place to stop fuel seeping, and slip the new rubber pipe back over the fuel line.

Finally, re-check the two bolts to the block and the clips to ensure they are all secure. You don't want a fuel or oil leak from the back of the pump. Crank the engine to make sure all is correct before trying to start the car fully.

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