Katerina Swanson
The fuel gauge sender is a component in your car's fuel tank that consists of a float connected to a metal rod, which is mounted to a resistor that measures electrical flow. If you own a 2009 Ford Expedition and your fuel gauge is faulty, you may need to replace the fuel sender. This can be done by disconnecting the battery, removing the fuel tank, taking out the defective fuel sender, installing a new one, and then reinstalling the fuel tank and reconnecting the battery. The cost of this replacement can vary depending on your location, but on average, it costs around $2222.61 to $3398.35, with parts costing $48 and labour costing $199.
| Characteristics | Values |
|---|---|
| Average cost for replacement | $247 with $48 for parts and $199 for labor |
| Shop/Dealer Price | $2222.61 - $3398.35 |
| Fuel gauge sender location | Inside the car's fuel tank |
| Fuel gauge sender function | It consists of a float that is connected to a metal rod. The end of this thin rod is mounted to a resistor, which measures electrical flow. |
| Fuel gauge sender failure symptoms | Fuel gauge only reads empty, full, or inaccurately/intermittently |
| Fuel level sending unit location | Inside the fuel tank |
| Fuel level sending unit function | Sends a constant signal indicating the amount of fuel that remains in a fuel tank |
| Fuel level sending unit failure symptoms | Fuel gauge will fail to operate, and, in some vehicles, the check engine light may illuminate |
| Fuel pump function | Moves the gasoline from the tank, up through the fuel lines, through the fuel filter and on to the fuel rail where it reaches the fuel injectors |
| Fuel pump replacement procedure | Disconnect the negative battery cable, unbolt the gas tank retaining straps, disconnect the fuel pump wiring and fuel lines, disconnect the fuel filler neck, remove the old fuel pump, install the new fuel pump, and reconnect the fuel pump wiring harness, fuel lines, and fuel filler neck |
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What You'll Learn
Disconnect the negative battery cable
Disconnecting the negative battery cable is a crucial first step when replacing the fuel sender in your 2009 Ford Expedition. Here is a detailed, step-by-step guide on how to do it safely and effectively:
Locate the Negative Battery Terminal: Under the hood of your Ford Expedition, identify the negative battery terminal. It is typically marked with a "-" symbol or a black cover.
Gather Appropriate Tools: Before proceeding, ensure you have the necessary tools for the job. You will need a suitable socket wrench or a box-end wrench that fits the nut securing the negative battery cable.
Loosen the Nut: Using your wrench, loosen the nut that secures the negative battery cable to the terminal. You may need to hold the terminal in place with one hand while turning the nut counterclockwise with the other.
Detach the Cable: Once the nut is loosened, carefully remove it by hand or with a suitable pair of pliers. Set the nut aside in a safe place so you don't lose it.
Isolating the Cable: After removing the nut, gently pull on the negative battery cable to detach it from the battery terminal. Ensure that you do not damage or deform the cable during this process.
Insulate the Cable: As a safety precaution, it is recommended to cover the exposed end of the negative battery cable with electrical tape or a suitable insulator. This will prevent accidental contact with the battery terminal, which could cause a short circuit.
By following these steps, you will have successfully disconnected the negative battery cable in your 2009 Ford Expedition. Remember to exercise caution when working with your vehicle's electrical system, and always refer to your owner's manual for additional safety information and guidelines.
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Remove the gas tank retaining straps
To remove the gas tank retaining straps, you'll need to first release the fuel system pressure and drain the fuel tank. Then, disconnect the vapor hoses at the rear of the tank. If your Expedition has a fuel tank skid plate, remove it.
Next, disconnect the vapor hose and the fuel hose(s) forward of the tank. Position a suitable jack under the tank, being careful not to support it directly beneath the fuel pump mounting area as this can cause damage to the fuel pump assembly.
Now you can remove the front and rear support straps and lower the front of the tank. You may need to remove the rear sway bar bracket nuts and lower the sway bar to do this.
Once the straps are removed, you can continue with the fuel sender replacement procedure.
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Disconnect the fuel pump wiring and fuel lines
Disconnecting the fuel pump wiring and fuel lines is a crucial step in replacing the fuel sender in a 2009 Ford Expedition. Here is a detailed guide on how to do this safely and effectively:
Before beginning any work on your Ford Expedition's fuel system, it is imperative to ensure your safety. Never work on a fuel system while smoking or near open flames. Fuel in the fuel system remains under high pressure, even when the engine is turned off. Always relieve the fuel system pressure before servicing or disconnecting any fuel lines or components. This can be done by releasing the fuel system pressure and draining the fuel tank.
Now, to access the fuel pump and its wiring, you will need to lower the fuel tank. Position a floor jack under the rear of the Expedition, centering it under the gas tank. Lift the jack until it touches the bottom of the tank. Next, unbolt the gas tank retaining straps and lower the tank several inches, creating enough space to reach your arm between the tank and the bottom of the vehicle.
With the fuel tank lowered, you can now disconnect the fuel pump wiring and fuel lines. First, disconnect the fuel pump wiring harness by hand. The fuel pump is located in the top-center of the gas tank. Then, disconnect the fuel lines from the fuel pump. Be cautious when handling the fuel lines, as they are critical to the fuel system's operation. Ensure that you note the routing of the fuel lines and the fuel vent hose to facilitate proper reconnection during reassembly.
At this point, the fuel pump wiring and fuel lines should be successfully disconnected from the fuel pump. You can now proceed to remove the fuel pump itself. Wrap a rag around the tip of a screwdriver and place it against the fuel pump retaining ring. Tap the handle of the screwdriver with a rubber mallet until the retaining ring turns loose in a counterclockwise direction. Lift the old fuel pump out of the gas tank, and you are ready to install the new one.
Remember to exercise caution when working with fuel system components, and always refer to a qualified mechanic or a professional repair guide if you are unsure about any steps in the process.
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Remove the fuel filler neck
To remove the fuel filler neck on a 2009 Ford Expedition, you will need to purchase a replacement filler neck. This can be purchased online or from a Ford dealership. The cost of the part is around $500, but this will vary depending on your location.
Once you have the new part, follow these steps:
- Remove the hose clamps that connect the filler neck to the fuel tank.
- Scrape away any rust, paint, or debris from the area where the filler neck meets the hoses.
- Remove the three bolts holding the filler neck to the fuel filler area. These are 7mm bolts, and you may need to use vice grips to remove them if they are stuck.
- Take a pry bar and remove the upper portion of the filler neck through the opening, giving you more room to work.
- Separate the hoses from the old filler neck tubes. This may require some force and the use of vice grips or a similar tool.
- Clean the inside of the hoses to remove any rust or debris.
- Insert the new filler neck tubes into the hoses, ensuring they are seated properly. There is a groove on the tubes that should sit about 2" into the hose.
- Reinstall the bolts at the gas cap to secure the new filler neck in place.
- Reattach the hose clamps and tighten them to complete the installation.
The whole process should take around 90 minutes. Once you have filled up the tank, check for any leaks to ensure the new filler neck has been installed correctly.
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Remove the fuel pump retaining ring
To remove the fuel pump retaining ring on a 2003 Ford Expedition, you will need to remove the fuel tank from the vehicle. Here is a step-by-step guide on how to do this:
- Release the fuel system pressure.
- Drain the fuel tank.
- Disconnect the vapor hoses at the rear of the fuel tank.
- If equipped, remove the fuel tank skid plate.
- Disconnect the vapor hose and the fuel hose(s) forward of the fuel tank.
- Position a suitable jack under the fuel tank, being careful not to support the fuel tank directly beneath the fuel pump mounting area, as this can cause 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 25 mm (1 inch).
- Remove the rear LH and RH sway bar bracket nuts and lower the sway bar.
- Remove the rear driveshaft.
- Loosen the clamp and disconnect the vent hose from the fuel tank vent spout.
- Disconnect the fuel pump electrical connector.
- Remove the fuel tank from the vehicle.
Once the fuel tank has been removed, you can access the fuel pump retaining ring. Here is a step-by-step guide on how to remove the retaining ring:
- Disconnect the quick-release fittings from the fuel pump.
- Remove the fuel pump lock ring. Ford uses a special tool for this, but it may also be possible to do it without the tool.
- Carefully remove the fuel pump assembly, being cautious not to damage the fuel level sensor.
- Note the location of the fuel pump alignment tabs and remove the O-ring.
- Remove the fuel level sensor.
It is important to exercise extreme caution when working with fuel-related components. Highly flammable mixtures are always present, and any open flame or spark can result in a fire or explosion. Always relieve the fuel system pressure before servicing or disconnecting any fuel lines or components.
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