1991 Ford Explorer: Fuel Pump Removal Process

• 1). Lay beneath the rear bumper of the Explorer and slide your body so that you are in position to see and physically access the fuel tank and its components. Set the jack beneath the fuel tank, and place a length of wood (1-foot long by 4-inches wide by variable thickness) on top of the jack, between the fuel tank and jack. Raise the jack so that the created platform rests against the bottom of the fuel tank, between the 2-fuel tank straps. Do not push on the bottom of the fuel tank, or you risk damaging the tank.
  
  
• 2). Remove the fuel filler neck from the outer side of the fuel tank, using a 1/4-inch ratchet and socket set. Remove the hose clamps with the ratchet and socket closest to the tank. Place one hand on the filler hose, and slide the fill tube inward, inside the fuel tank. The metal portion of the fill tube is held in by a rubber o-ring or grommet, so the fuel filler tube can be pushed into the tank with the right amount of force. Try not to move the rubber part of the filler neck from the body of the Explorer, as it could separate at the top.
  
  
• 3). Remove the fuel vapor return tube (parallel, next to filler neck) by separating the metal portion of the tube from the rubber portion of the tube. Use a 1/4-inch ratchet and socket to remove the hose clamp, and slide the rubber hose off of the metal tube. A slight twisting motion on the rubber end may be necessary, as corrosion usually bonds the rubber tube to the metal hose. Do not twist or push excessively, as this may damage or break the seal of the rubber hose at the top of the filler neck area.
  
  
• 4). Remove the 2-fuel tank straps, using a 3/8-inch drive ratchet and socket set. You can utilize a metal tube over the ratchet handle as an extension to provide you with more torque. Do not worry about damaging or snapping the mounting bolts or hardware, as these items are going to be replaced in the installation portion of this project. Years of corrosion, rust and oxidation can ruin the mounting bolts and nuts, essentially welding them together. Use whatever force is necessary to remove the fuel tank strap bolts and nuts from the Explorer.
  
  
• 5). Move the fuel tank straps out from underneath the fuel tank. The fuel tank should now be resting upon the jack and the created platform between the jack and tank. Lower the jack so that the tank drops halfway between the ground and the truck body, so that you can access the top of the fuel tank.
  
  
• 6). Remove the electrical connector from the top of the fuel pump, using your hand. Squeeze the tabs on the connector while simultaneously pulling the connector free of the fuel pump. Remove the fuel hoses from the top of the fuel pump, using a 1/4-inch drive ratchet and socket to remove the hose clamps. Slide the hoses off of the tube once the clamps have been loosened.
  
  
• 7). Lower the fuel tank to the ground once the electrical connector and fuel hoses have been removed from the top of the pump. Slide the fuel tank slowly out from the rear of the Explorer, or slide it out the side of the truck.
  
  
• 8). Remove the fuel filler tube (metal tube in the side of the tank) from the fuel tank completely. Install a large funnel into an empty gas can. Tip the open side of the fuel tank over the funnel, so that the existing fuel in the tank drains into the gas can. Repeat this step until you have completely emptied the fuel tank. Replace the fuel filler neck into the tank when you are finished emptying the tank.
  
  
• 9). Set the fuel tank on the ground. Use a hammer and flat head screwdriver to gently tap the fuel pump o-ring or lock ring so that it comes loose. Place the head of the screwdriver against the upward protruding metal tabs on top of the fuel pump. Tap the end of the screwdriver, so that the lock ring turns counterclockwise. Continue tapping the lock ring until it pops free of the fuel pump and tank.
  
  
• 10
  
  Remove the fuel pump by pulling the pump straight up vertically, out of the fuel tank. Place the old fuel pump in a drain pan for no less than a 12-hour period. (See "Tips" section for proper disposal of fuel pump and old fuel.)
  
  

1991 Ford Explorer: Fuel Pump Installation

• 1). Insert the new fuel pump into the top of the removed fuel tank. Make sure that the fuel hose tabs and electrical connector are facing the same way as the pump that was removed. If you forgot the direction the pump was facing, you can take a look under the truck again to visually confirm which way the components need to face.
  
  
• 2). Set the fuel tank lock ring onto the fuel pump. Push the lock ring down by hand and align the horizontal lock tabs with the tabs protruding from the tank. Tap the fuel tank lock ring into position by using a hammer and flat head screwdriver to move the ring.
  
  
• 3). Place the fuel tank back onto the jack with the wooden platform atop the jack. Raise the jack so that the fuel tank lifts back up halfway between the ground and the bottom of the truck.
  
  
• 4). Fasten the fuel hoses back to the fuel pump. Tighten the hose clamps using a 1/4-inch drive ratchet and socket. The clamps should be tightened between 20 to 30 foot-pounds of torque. Reconnect the electrical connector by pushing the connector into the pump until it snaps into place.
  
  
• 5). Lift the tank and align the tank so that it rests in its original position. Slide the fuel filler tube back into the fuel filler neck and tighten the hose clamp between 20 to 30 foot-pounds of torque, using a 1/4-inch ratchet and socket. Insert the fuel vapor return tube back into the rubber return hose, and tighten the clamps between 20 to 30 foot-pounds of torque, using a 1/4-inch ratchet and socket.
  
  
• 6). Slide the fuel tank straps back into position underneath and around the fuel tank. Set a 3/8-stainless washer on a 3/8-inch by 1 1/2-inch carriage bolt. Insert the bolt and washer combination downward through the old tank bolt hole. Press the tank strap upward with one hand. Install a second washer on the outside of the fuel tank strap and start a 3/8-stainless nut onto the carriage bolt by hand. Repeat this step to install and start the second fuel tank strap onto the Explorer.
  
  
• 7). Tighten the new fuel tank strap bolt and nut combination between 80 to 90 foot-pounds of torque. Do not overly tighten the new hardware, or you could break it.
  
  
• 8). Add 3 gallons of fuel back into the fuel tank. Turn the ignition key to the "II" or accessories position and then back off. Turn the key on and off at least 4 times, without starting the Explorer. Turning the key to the accessories position allows the new pump to prime the fuel lines and upper intake with fuel. Lack of fuel at start-up can cause severe engine damage. Turn the truck on after priming it at least 4 times. Add the remainder of the fuel if desired, or add new fuel at a gas station.