Safety First!
* Disconnect the negative battery terminal before starting any work. This prevents accidental sparks and shorts.
* Work in a well-ventilated area. Fuel fumes are dangerous and explosive.
* Wear safety glasses and gloves.
* Have a fire extinguisher readily available.
General Steps (This is a simplified overview. Consult a repair manual for specific details):
1. Prepare the Vehicle: Park the Expedition on a level surface, engage the parking brake, and chock the wheels.
2. Access the Fuel Pump: This usually involves dropping the fuel tank. The process varies depending on whether your Expedition has a fuel tank access panel (some do, some don't). You'll likely need to:
* Lower the fuel tank: This usually involves disconnecting the fuel lines, electrical connector, and tank straps. Be extremely careful with the fuel lines – they are under pressure even after the battery is disconnected. You'll need to relieve this pressure. A fuel pressure gauge and release tool are helpful.
* Alternatively, some models allow access through an access panel in the bed of the truck. Check your repair manual carefully.
3. Disconnect the Fuel Pump: Once the tank is lowered (or accessed through the panel), you'll need to:
* Disconnect the electrical connector to the fuel pump.
* Disconnect the fuel lines. Use fuel line clamps to prevent spills.
* Remove the fuel pump assembly. This often involves removing a retaining ring or bolts securing the pump to the tank.
4. Install the New Fuel Pump: Follow the reverse procedure of removal, ensuring:
* The new pump is correctly seated in the tank.
* All electrical connectors and fuel lines are securely connected and leak-free. Use new seals and clamps as needed.
* Tighten all bolts and clamps to the manufacturer's specifications.
5. Reinstall the Fuel Tank: Carefully raise the fuel tank back into its position and secure it with the straps. Reconnect the fuel lines and electrical connector.
6. Reconnect the Battery: Reconnect the negative battery terminal.
7. Check for Leaks: Carefully inspect all connections for leaks.
8. Start the Engine: Start the engine and check for any problems. Listen for unusual noises from the fuel pump. Check for fuel leaks.
Important Considerations:
* Fuel Tank Pressure: Failing to properly relieve pressure in the fuel system can result in fuel spraying during the repair. This is a serious fire hazard.
* Fuel Line Connections: Incorrectly connecting fuel lines can cause serious damage.
* Fuel Pump Electrical Connector: Damage to the connector can prevent the pump from functioning.
This is a complex repair with potential for serious injury or damage. If you're not comfortable performing this repair, it's strongly recommended you take your vehicle to a qualified mechanic. They have the tools, experience, and knowledge to do the job safely and correctly. The cost of a professional repair may be less than the cost of a mistake.
