Safety First!
* Disconnect the negative battery terminal before starting any work on the fuel system. This prevents accidental sparks that could ignite fuel vapors.
* Work in a well-ventilated area. Fuel vapors are extremely flammable and dangerous.
* Wear safety glasses and gloves.
* Have a fire extinguisher readily available.
Tools and Materials You'll Need:
* New fuel pump assembly: Make sure you get the correct one for your specific Expedition model and engine.
* Fuel pump socket: This is a special socket designed to grip the fuel pump retaining ring. You can sometimes rent this from auto parts stores.
* Wrench set: Various sizes to remove clamps, bolts, and lines.
* Screwdrivers (Phillips and flathead): For removing access panels and other fasteners.
* Fuel line disconnect tool: This helps safely disconnect the fuel lines without damaging them.
* Jack and jack stands: To safely lift the vehicle.
* Shop rags or absorbent towels: To clean up any spilled fuel.
* Fuel pressure gauge (optional but recommended): To ensure the fuel system is properly depressurized.
* Torque wrench: To tighten bolts to the manufacturer's specifications.
* Safety glasses and gloves.
* Fuel-safe container: To collect any remaining fuel in the tank.
General Steps:
1. Depressurize the Fuel System: This is crucial to avoid fuel spraying when disconnecting fuel lines. You can do this by starting the engine and letting it run until it stalls (due to fuel starvation), or by using a fuel pressure gauge to relieve pressure. Consult your repair manual for the specific method for your Expedition.
2. Lower the Fuel Tank: This is usually the most challenging part. You'll need to access the fuel pump usually located under the rear seat or in the bed of the truck (depending on the trim level). This often involves disconnecting fuel lines, electrical connectors, and possibly other components. You might need to use straps to support the tank while lowering it. Your repair manual will provide detailed steps.
3. Remove the Fuel Pump Access Panel: Once the tank is lowered (or in some cases, partially lowered), you'll find an access panel that allows you to reach the fuel pump.
4. Remove the Old Fuel Pump: Use the special fuel pump socket to carefully remove the retaining ring holding the fuel pump in place. Disconnect the electrical connector and fuel lines.
5. Install the New Fuel Pump: Carefully install the new fuel pump assembly, ensuring that the o-rings are properly seated. Reconnect the fuel lines and electrical connector securely.
6. Raise the Fuel Tank: Carefully raise the fuel tank back into its position. Secure all connections and fastenings.
7. Reconnect the Fuel Lines: Use caution and ensure there are no leaks.
8. Reconnect the Battery: Reconnect the negative battery terminal.
9. Start the Engine: Check for any leaks and ensure the engine starts and runs normally.
Important Considerations:
* Fuel System Safety: Always be mindful of fuel vapors and take appropriate safety precautions.
* Repair Manual: A factory service manual or a Haynes/Chilton repair manual for your specific year and model is essential. These provide detailed diagrams and instructions.
* Professional Help: If you are not comfortable performing this repair yourself, it's best to take your Expedition to a qualified mechanic. This is a relatively complex repair that could lead to damage if not done correctly.
This is a general guide. The exact procedure may differ depending on the specific model of your 2003 Ford Expedition. Always refer to your vehicle's repair manual for detailed instructions specific to your vehicle. Improperly performing this repair could result in serious injury or damage to your vehicle.
