How to Remove a '97 Ford Expedition Fuel Pump

The 1997 Ford Expedition was available with a 4.6-liter, or 5.4-liter overhead cam V-8 engine. Both engines use sequential electronic fuel injection, with individual fuel injectors mounted in the intake manifold ports. The fuel pump on the Expedition is attached to the fuel sending unit in an assembly in the fuel tank. The fuel pump can be removed from the assembly. The fuel tank must be removed from the Expedition to access the pump.

Instructions

Park the Expedition on a level, paved surface and set the parking brake. If the fuel tank is not near empty, use a siphon pump and gas can to remove as much gasoline from the tank as possible.

Relieve the fuel pressure by disconnecting the fuel pump inertia switch. The switch is located behind the plastic kick panel in the passenger compartment just in front of the door. Pull off the panel. It is held on with clips. Unplug the electrical connector from the inertia switch.

Start the engine. It will run for a few seconds and die. This indicates that the fuel system pressure is relieved. Disconnect the negative battery cable with a ratchet and socket.

Block the front wheels with wheel chocks. Raise the rear of the Expedition with a jack and support with jack stands. Move under the fuel tank and use a ratchet and socket to remove the bolts from the skid plate that protects the bottom of the fuel tank. Remove the skid plate.

Move under the fuel tank and locate the fuel filler and vent hoses. Loosen the hose clamps at the filler neck and pull the filler and vent hoses from the neck. Loosen the clamps where the hoses attach the fuel tank and remove the hoses from the fuel tank.

Unplug the sending unit and fuel pump electrical connectors. Support the fuel tank with a floor jack and a 2-by-4 inch piece of wood. Unbolt the fuel tank straps with a ratchet and socket and remove the straps. The front strap has two bolts. The rear strap has three bolts. Lower the tank enough so that you can reach the fuel lines. Put a strip of masking tape on one of the hoses and note which fitting it goes on.

Disconnect the fuel lines with a quick disconnect tool. Open the tool and fit it over the fuel line and coupling and close it. Push the tool into the cage on the fuel line and pull off the line. Remove the fuel lines. Have a shop rag handy to catch any fuel that may leak out of the lines. Lower the tank and slide it out from under the Expedition.

Note the alignment marks on the pump assembly and fuel tank. The pump has a small arrow that points at a dot on the tank. Unscrew the retaining ring with a large pair of channel-lock pliers. Turn it in a counter-clockwise direction. Lift the fuel pump assembly out of the tank, being careful not to damage the arm and float on the sending unit.

Discard the O-ring seal on the top of the fuel tank. Pry the C-clip from between the bottom of the fuel pump and the fuel strainer. Remove and discard the strainer. Loosen the clamp that holds the pump to the sending unit with a flat-had screwdriver. Remove the clamp.

Unplug the electrical connector at the fuel pump. Loosen the clamp on the hose it attaches to the fuel pump with a flat-head screwdriver. Remove the pump.

Attach the fuel line to the pump and tighten the clamp. Plug in the electrical connector. Slide the fuel pump clamp over the pump and sending unit. Tighten the clamp. Install a new strainer and insert the C-clip.

Apply a thin coat of multipurpose grease to a new fuel tank O-ring. Place the O-ring in a groove on the fuel tank. Lower the fuel pump into the tank. Alignment marks are on the pump assembly and fuel tank. Install and tighten the retaining ring.

Raise the tank far enough so that you can reconnect the fuel lines. Push the line onto the fitting and ensure that it is properly installed by pulling back on the line. It should snap into place. Repeat for the other fuel line. Raise the tank all the way into position. Pivot the fuel tank straps across the tank, install the bolts and torque them to 46 foot-pounds with a torque wrench.

Plug-in the sending unit and fuel pump connectors. Install the filler and vent hoses and tighten the clamps. Reattach the skid plate and torque the bolts to 46 foot-pounds. Raise the Expedition to remove the jack stands and lower it to the ground. Reconnect the inertia switch. If the button on the inertia switch pops up, reset it by pushing it down. Push the kick panel back onto the body. Reconnect the negative battery cable.