How to Replace a Fuel Pump on a '96 Explorer

Your 1996 Ford Explorer uses an in-tank, electric fuel pump to operate the fuel system. So, a pump failure means you need to drop the fuel tank in order to install a replacement. Although a somewhat involved process, the repair job is not as complex as it may look at first. You can accomplish this task with a few simple tools out of your toolbox on a Saturday morning. So gather your tools, replace the fuel pump and get your Explorer back on the road.

Things You'll Need

• Wrench set
• Hand siphon pump
• Approved gas container
• Floor jack
• 2 jack stands
• Ratchet
• Socket
• Large ratchet extension
• Fuel line disconnect tool
• New fuel pump assembly O-ring

Instructions

Removing the Old Fuel Pump

1. Park your Explorer on a level surface, open the hood and remove the fuel pump relay from the fuse/relay box. Start the engine and let it stall. Replace the fuel pump relay and disconnect the ground (black) battery cable with a wrench. This will properly relieve the fuel pressure system.

2. Remove the fuel tank filler cap, insert the hose of a hand siphon pump into the filler tube and drain as much gasoline as possible out of the fuel tank into a gas container. After draining the fuel, remove the hose and leave the filler cap loose.

3. Raise the rear of your Explorer with a floor jack and set it on two jack stands.

4. Crawl under the fuel tank and loosen the clamps on the tank fuel filler and vent hoses with a ratchet and socket. Pull off the hoses from their fittings.

5. Detach the fuel tank ground strap with the ratchet and socket.

6. Unplug the fuel pump electrical connector located right in front of the tank, mounted on the left (driver's-side) frame rail. Position the floor jack under the fuel tank for support with a block of wood between the jack's head and the tank to prevent damage to the tank.

7. Unfasten the tank holding strap with a ratchet, large ratchet extension and socket. Move the strap out of the way and unfasten the two mounting bolts securing the front of the tank to the vehicle's body with the ratchet, ratchet extension and socket.

8. Lower the fuel tank a few inches to gain access to the fuel lines connected to the fuel pump assembly on the tank. Disconnect the fuel feed, return and vapor lines from the pump assembly with a fuel line disconnect tool and lower the tank to the floor.

9. Note the alignment marks on the top of the fuel pump assembly and fuel tank. Unscrew the six bolts holding the fuel pump assembly to the fuel tank with a ratchet, ratchet extension and socket. Lift the pump assembly a couple of inches and then angle the assembly and carefully remove it out of the fuel tank. Discard the O-ring on the tank opening.

10. Loosen the clamp bolt holding the pump to the assembly with a wrench and slide down the pump out of the clamp. Unplug the pump electrical connector and detach the hose from the pump. Remove the pump from the assembly.

Installing the New Fuel Pump

1. Place the new pump in place on the assembly, connect the hose and plug in the electrical connector to the new pump. Install a new strainer to the bottom of the pump. Slide the pump into the holding clamp and tighten the bolt with the wrench.

2. Install a new O-ring on the tank opening. Reinstall the fuel pump assembly into the fuel tank, following the alignment marks, and tighten the six mounting bolts with the ratchet, ratchet extension and socket.

3. Raise the fuel tank just enough to connect the fuel feed, return and vapor lines to the pump assembly and lift the tank into its mounting position.

4. Tighten the two bolts to the front of the fuel tank and replace the tank holding strap with the ratchet, large ratchet extension and socket.

5. Remove the floor jack from the vehicle and plug in the fuel pump electrical connector.

6. Attach the fuel tank ground strap with the ratchet and socket.

7. Connect the tank fuel filler and vent hoses and tighten the clamps with the ratchet and socket.

8. Lower your Explorer off the jack stands.

9. Refill the fuel tank with the fuel you removed earlier and tighten the filler cap.

10. Reconnect the ground (black) battery cable with the wrench. Turn the ignition key to the "On" position to pressurize the fuel system. Start the engine and check for fuel leaks at the fuel tank and turn off the engine.

Tips & Warnings

• Most auto-parts stores carry siphoning kits you can use when servicing the fuel tank.

• To prevent a serious accident when working on the fuel system of your 1996 Ford Explorer, choose a well-ventilated area away from appliances fitted with open flames like water heaters and dryers.

References

• "Ford Explorer, Mazda Navajo, Mercury Mountaineer and Explorer Sport/Sport Trac Automotive Repair Manual"; Jay Storer and John H. Haynes; 2005
• "Modern Automotive Technology"; James E. Duffy; 2003