Replacing The Fuel Pump In A 1998 Ford Expedition

Replacing the fuel pump on a 1998 Ford Expedition can be a challenging task. While it is possible to access the fuel pump without dropping the gas tank, it requires careful manoeuvring in a tight space and several tools. Here's a step-by-step guide to help you get started:

1. Ensure the tank is almost empty, as a full tank will make the process more difficult.

2. Disconnect the battery and locate the fuel pump assembly, which is secured in the tank with a plastic ring.

3. Use a suitable tool, such as a crowbar and a dead blow hammer, to gently tap on the ring's grip tabs and loosen it. Be careful not to strip the threads.

4. Once the ring is loosened, carefully lift the fuel pump assembly out, being mindful of the fuel sender float arm and the gasket.

5. Install the new fuel pump, making sure to route the fuel vent hose and fuel tank pressure sensor correctly.

6. Secure the fuel pump assembly back into the tank by tapping the ring gently with the crowbar and hammer until it feels solid.

7. Reconnect the battery and fuel lines, and fill the fuel tank.

Note: Always exercise extreme caution when working with fuel-related components. Avoid open flames or sparks, and have a fire extinguisher nearby.

Release the fuel system pressure

To release the fuel system pressure on a 1998 Ford Expedition, you must first locate the fuel rail. This is the chrome pipe that runs between all of the injectors. There should be a plastic cap that you can unscrew. Underneath this, you will find the pressure check port, which looks like a regular tyre valve.

With the ignition key in the 'off' position, push the valve in to release the fuel pressure. Fuel will also be released, so be sure to have a rag to hand. Do not look into the valve when you push it.

Drain the fuel tank

To drain the fuel tank of a 1998 Ford Expedition, you will need to follow these steps:

Firstly, ensure you are working in a well-ventilated area, and that no open flames or sparks are present as you will be handling flammable liquids. It is also recommended that you wear safety goggles and gloves. Begin by releasing the fuel system pressure. Next, locate and disconnect the vapor hoses at the rear of the fuel tank. If your vehicle is equipped with a fuel tank skid plate, remove this.

Now, position a suitable jack under the fuel tank—do not support the tank directly beneath the fuel pump mounting area, as this can cause damage to the fuel pump assembly. Lower the front of the fuel tank by approximately 25mm (1 inch).

At this stage, you can begin to drain the fuel from the tank. Use a suitable container to collect the fuel and ensure you are adhering to safety guidelines when handling and disposing of the fuel. Once the tank is empty, you can proceed to the next steps in removing the fuel pump.

Disconnect the vapor hoses at the rear of the fuel tank

To disconnect the vapor hoses at the rear of the fuel tank of your 1998 Ford Expedition, you will need to first release the fuel system pressure and drain the fuel tank. Once this is done, you can then disconnect the vapor hoses at the rear of the fuel tank.

It is important to note that the 4.6L and 5.4L (2V) engines are equipped with returnless fuel systems, while the 5.4L 4V engine is equipped with a return-type fuel system. Therefore, if you have a 4.6L or 5.4L (2V) engine, you will also need to disconnect the vapor hose and the fuel hose(s) forward of the fuel tank.

Additionally, make sure to not support the fuel tank directly beneath the fuel pump mounting area, as this can cause damage to the fuel pump assembly. Instead, position a suitable jack under the fuel tank.

Finally, note the routing of the fuel vent hose and then remove the fuel tank front and rear support straps, lowering the front of the fuel tank by approximately 25 mm (1 inch).

Remove the fuel tank skid plate

To remove the fuel tank skid plate from a 1998 Ford Expedition, follow these steps:

Firstly, ensure that you have the necessary tools and safety equipment. This includes eye protection, gloves, and a suitable jack. It is also recommended to have a second person to help with the task.

Now, to the task at hand:

• Release the fuel system pressure.
• Drain the fuel tank.
• Disconnect the vapor hoses at the rear of the fuel tank.
• Remove the fuel tank skid plate.
• Position a jack under the fuel tank; do not support the tank directly beneath the fuel pump mounting area to avoid damage to the fuel pump assembly.
• Remove the fuel tank front and rear support straps, and lower the front of the fuel tank by approximately 25mm or 1 inch.

At this point, you should have successfully removed the fuel tank skid plate from your 1998 Ford Expedition. Remember to exercise caution when working with fuel systems and always refer to the owner's manual or a qualified mechanic if you are unsure about any steps.

Disconnect the vapor hose and the fuel hose(s) forward of the fuel tank

To disconnect the vapor hose and the fuel hose(s) forward of the fuel tank, you will need to purchase a fuel and auto trans line disconnect tool. This can be bought at most auto parts stores and costs around $10.

Using the tool, clamp it around the line and push it into the disconnect. This will lower the "teeth" of the disconnect and allow the female fitting to slip out over the male part of the disconnect.

Make sure you do this for both the vapor hose and the fuel hose(s).

It is critical that you do not support the fuel tank directly beneath the fuel pump mounting area, as this can cause damage to the fuel pump assembly.

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