Sylvie Willis
If you're looking to remove the fuel tank from your 2003 Ford Expedition, there are a few things you should know. Firstly, electric fuel pumps are generally mounted inside the fuel tank, and it's important to relieve the fuel system pressure before starting any work to prevent accidental spraying of fuel. You will also need to drain the fuel tank and disconnect the vapor hoses at the rear of the tank. Additionally, the fuel pump lock ring can be a challenge to remove, and you may need a special tool for this step. It is recommended to take your vehicle to a service center or dealership to have them diagnose and address any issues with your fuel tank or pump.
| Characteristics | Values |
|---|---|
| Fuel tank removal process step 1 | Release the fuel system pressure |
| Fuel tank removal process step 2 | Drain the fuel tank |
| Fuel tank removal process step 3 | Disconnect the vapor hoses at the rear of the fuel tank |
| Fuel tank removal process step 4 | Remove the fuel tank skid plate (if equipped) |
| Fuel tank removal process step 5 | Disconnect the vapor hose and the fuel hose(s) forward of the fuel tank |
| Fuel tank removal process step 6 | Position a suitable jack under the fuel tank (do not support the fuel tank directly beneath the fuel pump mounting area) |
| Fuel tank removal process step 7 | Remove the fuel tank front and rear support straps and lower the front of the fuel tank |
| Fuel tank removal process step 8 | Remove the rear LH and RH sway bar bracket nuts and lower the sway bar |
| Fuel tank removal process step 9 | Remove the rear driveshaft |
| Fuel tank removal process step 10 | Loosen the clamp and disconnect the vent hose from the fuel tank vent spout |
| Fuel tank removal process step 11 | Disconnect the fuel pump electrical connector |
| Fuel pump removal process step 1 | Disconnect the quick-release fittings from the fuel pump |
| Fuel pump removal process step 2 | Remove the fuel pump lock ring (Ford uses a special tool) |
| Fuel pump location | Inside the fuel tank |
| Fuel pump replacement cost | $611 to $894 (including parts and labor) |
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What You'll Learn
Release the fuel system pressure
It is imperative to relieve the fuel system pressure before removing the fuel tank from a 2003 Ford Expedition. This is because the fuel in the system remains under high pressure, even when the engine is not running. Releasing the pressure prevents accidental spraying of fuel, reducing the risk of personal injury or a fire hazard.
Step 1: Safety Precautions
- Ensure the engine is not running.
- Do not smoke, carry lighted tobacco, or open flames near the fuel system. The presence of highly flammable mixtures can easily ignite, leading to potential harm or injury.
Step 2: Locate the Fuel Rail
The fuel rail is a chrome pipe that runs between all the injectors. It should be easily accessible.
Step 3: Identify the Pressure Check Port
On the fuel rail, you will find a plastic cap. Unscrew this cap to reveal the pressure check port underneath. It resembles a regular tire valve.
Step 4: Release the Pressure
With the ignition key in the "OFF" position, push the valve in. You will notice a release of fuel pressure, so have a rag ready to absorb any spillage. It is important not to look directly into the valve when pushing it.
Step 5: Confirm Fuel System Pressure Release
To ensure the pressure has been adequately released, you can perform a simple check. With the ignition key in the "ON" position and the engine "OFF," use a fuel pressure gauge to verify if the pressure has dropped to 0 psi.
Step 6: Optional Fuel Pump Check
If you suspect an issue with the fuel pump, you can perform a quick test. Run a fused wire directly from the battery to the fuel pump. If the pump still doesn't operate, it may be faulty and require replacement.
By following these steps, you will safely release the fuel system pressure in your 2003 Ford Expedition. Remember to exercise caution and seek professional advice if you are unsure about any part of the process.
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Disconnect the vapor hoses
Before disconnecting the vapor hoses of a 2003 Ford Expedition, it is important to take safety precautions. The fuel system remains under high pressure even when the engine is not running, so the fuel system pressure must be relieved to prevent accidental spraying of fuel, which could cause injury or a fire hazard.
To disconnect the vapor hoses:
- Ensure you are wearing the appropriate safety gear, including eye protection and gloves.
- Locate the vapor hoses at the rear of the fuel tank.
- Using a suitable tool, such as a fuel filter release tool or a fuel line disconnect tool, carefully disconnect the vapor hoses.
- Pay attention to the routing of the fuel vent hose, as its location is critical to the fuel system's operation.
- Once the vapor hoses are disconnected, set them aside or label them for future reference if needed.
It is important to note that working on a fuel system can be dangerous, and it is always recommended to have a qualified technician perform any repairs or maintenance if you are unsure or uncomfortable with the process.
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Remove the fuel tank skid plate
To remove the fuel tank skid plate from a 2003 Ford Expedition, you will need to follow a series of steps. Firstly, it is important to exercise caution when working with fuel-related components. Ensure that you do not smoke or have any open flames nearby as highly flammable mixtures are always present. The next step is to release the fuel system pressure and drain the fuel tank. This is crucial to prevent accidental spraying of fuel, which could lead to personal injury or a fire hazard.
Once the fuel system pressure is released, you can proceed to disconnect the vapor hoses at the rear of the fuel tank. Be mindful of the location of the fuel vent hose, as it is critical to the fuel system operation. After disconnecting the hoses, you may need to remove the fuel tank skid plate, depending on your vehicle's configuration.
To access the fuel pump, you can either work through an access panel in the passenger compartment or remove the fuel tank from the vehicle. If you choose to remove the fuel tank, position a suitable jack under it, ensuring you do not support it directly beneath the fuel pump mounting area to avoid damage to the fuel pump assembly.
Finally, to remove the fuel tank skid plate, you will need to lower the fuel tank by removing the front and rear support straps. This will allow you to access and remove the skid plate. It is important to follow these steps carefully and seek professional assistance if needed to ensure a safe and successful fuel tank skid plate removal.
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Disconnect the fuel pump electrical connector
Before disconnecting the fuel pump electrical connector, it is important to take several safety precautions. Ensure that you are not smoking or carrying any lighted tobacco or open flame as highly flammable mixtures are always present in the fuel system and can be ignited, resulting in possible personal injury.
Additionally, the fuel system pressure must be relieved to prevent accidental spraying of fuel, which could also cause injury or create a fire hazard. This can be done by releasing the fuel system pressure and draining the fuel tank.
Now, to disconnect the fuel pump electrical connector, you will need to follow these steps:
First, disconnect the vapor hose and the fuel hose(s) forward of the fuel tank. Be cautious not to support the fuel tank directly beneath the fuel pump mounting area, as this can damage the fuel pump assembly. Instead, position a suitable jack under the fuel tank.
Second, note the routing of the fuel vent hose and remove the fuel tank front and rear support straps. Lower the front of the fuel tank by approximately 25 mm or 1 inch.
Third, remove the rear left and right sway bar bracket nuts and lower the sway bar.
Fourth, remove the rear driveshaft.
Fifth, loosen the clamp and disconnect the vent hose from the fuel tank vent spout.
Finally, you can disconnect the fuel pump electrical connector.
It is important to note that these steps are based on general instructions for removing the fuel pump and fuel tank in a Ford Expedition. For specific instructions regarding your 2003 Ford Expedition, it is recommended to refer to the vehicle's repair manual or seek advice from a qualified mechanic.
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Remove the fuel tank
To remove the fuel tank from a 2003 Ford Expedition, you must first release the fuel system pressure and drain the fuel tank. Next, disconnect the vapor hoses at the rear of the fuel tank. If equipped, remove the fuel tank skid plate.
Position a suitable jack under the fuel tank. Do not support the fuel tank directly beneath the fuel pump mounting area, as damage to the fuel pump assembly may occur. 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. Loosen the clamp and disconnect the vent hose from the fuel tank vent spout. Disconnect the fuel pump electrical connector.
Finally, remove the fuel tank from the vehicle.
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