Here's a general outline. Specific steps may vary slightly depending on your Explorer's engine (V6 or V8) and equipment. Always consult a repair manual specific to your vehicle's year, make, model, and engine for precise instructions and torque specifications.
Tools You'll Likely Need:
* Socket set (metric): Various sizes, including a deep well socket for the fuel pump retaining bolts.
* Wrench set (metric): For various fasteners.
* Fuel line disconnect tool: This is crucial to avoid damaging the lines.
* Torque wrench: To tighten bolts to the manufacturer's specifications.
* Jack and jack stands: To safely lift the vehicle.
* Wheel chocks: For safety.
* Safety glasses and gloves: Protect yourself.
* Shop rags: To clean up spills.
* New fuel pump and filter (if applicable): Make sure you get the correct part number for your vehicle.
* Fuel pump installation kit (optional but recommended): May include a new fuel sending unit gasket, etc.
* Large capacity drain pan: To catch the fuel that will drain out of the tank.
General Steps (Consult your repair manual for precise details):
1. Safety First: Disconnect the negative battery terminal. Let the vehicle sit for at least 15 minutes to allow any residual pressure to dissipate.
2. Lower the Fuel Tank: This usually involves lowering the fuel tank. This often requires removing the spare tire, lowering the exhaust system (at least partially), and disconnecting various components such as fuel lines, filler neck and vent hose. This is the most labor-intensive part of the job. Support the tank securely as you lower it.
3. Access the Fuel Pump: The fuel pump assembly is located inside the fuel tank. Once the tank is lowered enough, you'll have access to the fuel pump assembly.
4. Disconnect Electrical Connectors: Carefully disconnect the electrical connectors from the fuel pump. Take pictures to remember how they connect.
5. Disconnect Fuel Lines: Use the fuel line disconnect tool to carefully disconnect the fuel lines. Have rags ready to absorb any spilled fuel.
6. Remove the Fuel Pump Assembly: This usually involves removing several bolts securing the fuel pump assembly to the tank. Be careful not to damage the gasket.
7. Install the New Fuel Pump: Install the new fuel pump assembly, ensuring the gasket is properly seated. Tighten the bolts according to your repair manual's specifications.
8. Reconnect Fuel Lines and Electrical Connectors: Carefully reconnect the fuel lines and electrical connectors. Double-check everything.
9. Raise the Fuel Tank: Carefully raise the fuel tank back into its position. Reconnect all the lines and components that were disconnected.
10. Reconnect the Battery: Reconnect the negative battery terminal.
11. Test: Start the vehicle and check for leaks. Check for proper fuel pressure (this may require a fuel pressure gauge).
Important Considerations:
* Fuel Vapor: Fuel vapors are highly flammable and potentially explosive. Work in a well-ventilated area away from open flames and sparks.
* Fuel Pressure: There is often residual pressure in the fuel system. Take precautions to avoid injury.
* Repair Manual: A repair manual specific to your vehicle is essential. The steps above are a general guideline and may not be entirely accurate for your specific model.
This process is complex and potentially dangerous. If you are not comfortable performing this repair yourself, take your vehicle to a qualified mechanic. The cost of a professional repair is usually less than the cost of damaging your vehicle or injuring yourself.
