Replacing the fuel pump in your Ford Expedition may be a result of frequently driving until the gasoline tank is close to empty. It is best to change the fuel pump when the fuel level is very low, unless you can siphon the fuel out of the gas tank. The Expedition is a vehicle that stores the pump within the fuel tank, although it is mounted in a slightly different manner than other vehicles. You can also replace the pump separately from the assembly, unlike other vehicles.
Things You'll Need
- Fuel-pressure gauge
- Gasoline-safe container
- Floor jack
- Jack stands
- Wood block
Park the vehicle on a level surface and turn off the ignition. Raise and secure the vehicle's hood. Disconnect the negative battery cable with a wrench. Connect a fuel pressure gauge onto the pressure test port; this is located on the fuel rail near the center of the engine compartment. Turn the valve to bleed the fuel into a metal cup or other gas-safe container, relieving the fuel pressure.
Raise the truck's rear end with a jack and support it on jack stands. If there is a skid plate covering the gas tank, which is located behind the truck's fuel filler door, unbolt it with a wrench and remove it.
Disconnect the fill/vapor hoses from the tank neck, loosening the clamps with a screwdriver. Disconnect the fuel/EVAP lines at the quick-connect fittings and disconnect the pump electrical connector with a flat-head screwdriver, which are on or near the fuel pump flange.
Raise the floor jack with a block of wood on it under the tank to support it. Unbolt the tank straps, lower the jack and disconnect any remaining wire harnesses or lines by pressing the quick-connect fittings.
Highlight with a marker the alignment mark on the fuel tank that lines up with the mark on the fuel pump flange.
Remove the six bolts fastening the fuel pump module to the tank, using a small flare-nut wrench, and lift the module out of the tank.
Disconnect the electrical connector--the small two-part plug device underneath the pump--from the pump/sending unit assembly; use a small screwdriver if you cannot do it by hand. Remove the clamp's bolt with a small wrench to remove the pump from the assembly.
Install the fuel pump to the assembly with its clamp and electrical connector.
Lower the assembly into the tank, making sure you do not damage the new pump's strainer, and apply the mounting bolts. Make sure the alignment mark on the flange lines up with the one on the tank.
Raise the tank into position and secure it to the vehicle with its straps and strap bolts. Reconnect the fuel lines, electrical connectors and the fill/vapor hoses.
Reconnect the skid plate with its bolts, if applicable.
Lower the truck off the jack stands with the jack.
Tips & Warnings
- You can remove/install the tank without the use of the floor jack provided you have a second person to support it as you remove/connect the straps.
- Do not work near an open flame.
- Do not smoke while working on the fuel pump.
- "Chilton Ford Pick-ups Repair Manual"; Eric Mihalyi; Haynes North America; 2009
- Photo Credit Jupiterimages/Comstock/Getty Images
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