Replacing Fuel Sender In 2009 Expedition: Step-By-Step Guide

If you're looking to replace the fuel sender in your 2009 Ford Expedition, you'll need to disconnect the negative battery cable, remove the fuel tank retaining straps, and lower the tank to access the fuel pump. The pump is located in the top centre of the gas tank, and you'll need to disconnect the fuel pump wiring, fuel lines, and fuel filler neck. When installing the new pump, ensure the fuel level float is positioned correctly and doesn't contact the side of the tank. This process requires basic automotive repair skills and a few hours of free time. The average cost for this replacement service is between $1,199 and $3,398, with parts priced between $988 and $1,180, and labour costs between $211 and $2,217.

Disconnect the negative battery cable

Disconnecting the negative battery cable is an important first step when replacing the fuel sender in a 2009 Ford Expedition. This is a safety precaution to prevent electrical shocks or sparks, which could be dangerous when working with fuel. Here is a detailed, step-by-step guide on how to disconnect the negative battery cable:

Step 1: Locate the Negative Battery Cable

The negative battery cable is usually black and connected to the negative terminal of the battery, which is often marked with a "-" symbol. It is typically located in the engine bay, near the front of the vehicle.

Step 2: Prepare the Necessary Tools

You will need a few basic tools for this task, including a pair of safety gloves to protect your hands, a wrench or socket that fits the battery terminal, and possibly a pair of pliers. It is also recommended to have some clean rags or paper towels nearby in case of any spilled battery acid.

Step 3: Loosen the Negative Battery Cable

Before disconnecting the cable, make sure the vehicle is turned off and the engine is cool. Put on your safety gloves, then use the appropriate wrench or socket to loosen the nut or bolt that secures the negative battery cable to the terminal. Turn it counterclockwise to loosen it. If the connection is tight, you may need to use a pair of pliers for extra leverage.

Step 4: Disconnect the Cable

Once the nut or bolt is loosened, carefully remove it by hand or with the pliers. Be cautious not to let it drop and potentially short-circuit on any metal parts of the vehicle. Now, gently pull the negative battery cable away from the terminal. If it feels stuck, wiggle it gently until it comes free. Be careful not to touch the positive terminal or any other metal parts with the cable.

Step 5: Secure the Cable

After the cable is disconnected, make sure to secure it away from the battery and any metal surfaces. You can use a cable tie or tape to hold it in place. This will prevent accidental contact or short circuits while you work on the fuel sender.

Step 6: Verify Disconnection

Double-check that the negative battery cable is indeed disconnected from the terminal. This step is crucial, as any accidental contact can be hazardous. Ensure the cable is securely isolated and cannot come into contact with the battery or any metal parts during the fuel sender replacement process.

Remember, working with electricity and fuel can be dangerous, so it is essential to take your time and follow these steps carefully. Once you have completed these steps, you can proceed with the rest of the fuel sender replacement procedure, which may involve removing the fuel tank and accessing the fuel pump and sending unit. Always refer to a qualified mechanic or a detailed repair guide for the next steps in the replacement process.

Jack up the rear of the car to access the gas tank

To replace the fuel sender in a 2009 Ford Expedition, you'll need to jack up the rear of the car to access the gas tank. Here's a detailed, step-by-step guide on how to do this safely:

Park your car on a flat, sturdy surface, such as a level parking lot or driveway. Make sure you're away from traffic and use hazard lights, cones, or reflective triangles if necessary.

Place wheel chocks or other barriers, such as bricks or cinder blocks, in front of the wheels on the opposite side of the car to the side you intend to jack up. This will prevent the car from rolling. Ensure the car is in "Park" and engage the parking brake.

Consult your owner's manual to locate the jack points on your Ford Expedition. These are reinforced points along the body where the vehicle is designed to be lifted. Typically, there are jack points behind the front wheels and in front of the rear wheels, near the rocker panels.

Position your car jack under one of the jack points at the rear of the car. Make sure the jack is facing the correct way up—check the jack's user manual if it's not labelled.

Use the jack handle to raise the jack until it touches the car. Continue raising it until the rear wheels are lifted 3-6 inches (7.6-15.2 cm) off the ground. This will give you enough clearance to access the gas tank.

For added safety, place a jack stand under the car, next to the jack. This will provide extra support in case the jack shifts or collapses. Ensure the jack stand is also positioned under a jack point.

With the car securely jacked up, you can now access the gas tank to replace the fuel sender. Remember to work with a helper, if possible, and follow standard safety precautions when working with fuel.

Once you've finished the repair or maintenance, gradually lower the car back to the ground by reversing the jacking process. Remove the jack and jack stand, and you're done!

Remove the gas tank retaining straps

To remove the gas tank retaining straps from your 2009 Ford Expedition, you will need a floor jack, a socket set, and a mallet. Here is a step-by-step guide:

• Position the floor jack under the gas tank: Roll the floor jack under the rear of the Expedition and centre it under the gas tank.
• Lift the jack head: Lift the jack head until it touches the bottom of the tank. Make sure the jack is stable and secure.
• Unbolt the gas tank retaining straps: Use the socket set to unbolt the retaining straps. There will be two bolts per strap. Be careful not to drop the bolts or straps inside the vehicle.
• Lower the gas tank: Lower the tank several inches until you can access the components and wiring. Keep the tank level as you lower it.
• Disconnect the wiring and hoses: With your arms now able to reach between the tank and the bottom of the Expedition, disconnect the fuel pump wiring and fuel lines from the fuel pump by hand.
• Remove the gas tank: Continue to lower the gas tank using the floor jack. Once it is low enough, roll the tank out from under the Expedition and set it on the ground.

Now that the retaining straps have been removed, you can proceed with the next steps to replace the fuel sender. Remember to exercise extreme caution when working with a fuel system. Do not smoke or work near open flames.

Disconnect the fuel pump wiring and fuel lines

Disconnecting the fuel pump wiring and fuel lines from your 2009 Ford Expedition can be a tricky process, but with care and attention, it can be done safely and effectively. Here is a step-by-step guide to help you through the process:

Step 1: Prepare the Vehicle

Before beginning any work on your vehicle, it is important to ensure that you have a safe and clean workspace. Park your Expedition on a level surface, engage the parking brake, and block the wheels to prevent accidental movement. Make sure you are wearing appropriate safety gear, including gloves and eye protection. Locate the fuel pump, which is housed within the fuel tank, and familiarise yourself with the surrounding components.

Step 2: Disconnect the Battery

Locate the negative battery terminal and disconnect it using an appropriate socket or wrench. This will prevent any accidental electrical shorts during the procedure.

Step 3: Locate the Fuel Lines

The fuel lines are connected to the fuel pump and are responsible for carrying fuel from the tank to the engine. They are usually secured with clamps or quick-disconnect fittings. In some cases, they may be held in place with spring clips or other fasteners. Identify the type of connection and ensure you have the appropriate tools to release them.

Step 4: Release the Fuel Lines

Depending on the type of connection, you may need to depress a tab or button to release the fuel line. In some cases, you may need to use a specialised fuel line disconnect tool to safely release the line without damaging the connector. Be gentle but firm when releasing the lines to avoid any spillage or damage.

Step 5: Disconnect the Fuel Pump Wiring

The fuel pump is controlled by electrical wiring that provides power and signalling. Locate the wiring harness connected to the fuel pump and carefully disconnect it. The wiring harness may have a locking mechanism or retaining clip that needs to be released before disconnecting. Take note of the wiring configuration to ensure proper reconnection during reassembly.

Step 6: Secure the Fuel Lines

Once the fuel lines and wiring are disconnected, it is important to secure them to prevent any accidental spillage or damage. Use suitable clamps or zip ties to hold the lines in place, ensuring they are away from any moving parts or hot surfaces.

By following these steps, you can safely and effectively disconnect the fuel pump wiring and fuel lines on your 2009 Ford Expedition. Remember to work carefully and consult a qualified mechanic if you are unsure about any part of the process.

Remove the old fuel pump and insert the new one

To remove the old fuel pump and insert the new one, follow these steps:

Firstly, disconnect the negative battery cable using a battery wrench. Push the cable end over so it cannot contact the battery terminal during the rest of the procedure. Next, roll a floor jack under the rear of the Expedition and centre it under the gas tank. Lift the jack head up until it touches the bottom of the tank.

Now, unbolt the gas tank retaining straps using a socket set. Lower the tank several inches until you can fit your arm between the tank and the bottom of the vehicle. Disconnect the fuel pump wiring and fuel lines from the fuel pump by hand. The pump is located in the top-centre of the gas tank. Also, disconnect the fuel filler neck from the tank using a screwdriver.

Lower the gas tank down using the floor jack, ensuring that it remains level. Roll the tank out from under the vehicle and set it on the ground. Wrap a rag around the tip of a screwdriver and place the tip against the fuel pump retaining ring. Tap the handle of the screwdriver with a rubber mallet until the retaining ring turns loose. You will need to turn the ring counter-clockwise.

Now, carefully lift the old fuel pump up and out of the gas tank. Lower the new pump down into the tank, ensuring that the fuel level float is positioned so that it does not contact the side of the tank. Tighten the retaining ring in the opposite direction to how you removed it.

Place the gas tank back onto the floor jack and roll it back under the vehicle. Raise the tank back into position and reconnect the fuel pump wiring harness, fuel lines, and fuel filler neck before raising the tank to its full height. Bolt the gas tank retaining straps back into position with the socket set. Roll the floor jack out from under the vehicle. Finally, reconnect the negative battery cable to the battery.

Frequently asked questions