Fuel pump access hatch
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New User
Joined: Mar 2016
Posts: 12
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From: Cheyenne, Wyoming
Fuel pump access hatch
Hey Folks,
Have any of you tried to cut an access hatch in the rear of your truck to get to the fuel pump without dropping the tank? Am I way off? can it even be done?
My fuel pump took a dump with about a quarter of a tank. I'm trying to find a work around.
Any ideas.... Please share.
Have any of you tried to cut an access hatch in the rear of your truck to get to the fuel pump without dropping the tank? Am I way off? can it even be done?
My fuel pump took a dump with about a quarter of a tank. I'm trying to find a work around.
Any ideas.... Please share.
Fleet Mechanic
Joined: Feb 2011
Posts: 1,812
Likes: 88
From: Thousand Oaks, CA
I did this on our 1st gen Explorer and it wasn't that hard, just had to take out the rear seat.
The hardest part is sealing the hole back up because the panels are not flat.
I cut out a larger piece from a junkyard car to make a cover plate that was caulked and screwed over the hole.
Moderator
Joined: Jul 2010
Posts: 12,050
Likes: 1,549
From: Media PA
Drop the tank. 
Seriously, dropping the tank, even with some gas in it will be easier, quicker and far less damaging to your EX. You can drain the fuel out once it's down (or do some siphoning before you drop it) so it's lighter and easier to handle going back up.
Taking the tank out is an easy job, I've done it twice now and could have it empty and sitting on the ground in about an hour with only a handful of hand tools and a floor jack.
I think it would be more work and time consuming to properly locate, mark, cut, fab a capturing/locating flange and reinstall the cut out section without it looking and performing like a less than perfect option.
Drop the tank.
Seriously, dropping the tank, even with some gas in it will be easier, quicker and far less damaging to your EX. You can drain the fuel out once it's down (or do some siphoning before you drop it) so it's lighter and easier to handle going back up.
Taking the tank out is an easy job, I've done it twice now and could have it empty and sitting on the ground in about an hour with only a handful of hand tools and a floor jack.
I think it would be more work and time consuming to properly locate, mark, cut, fab a capturing/locating flange and reinstall the cut out section without it looking and performing like a less than perfect option.
Drop the tank.
Fleet Mechanic
Joined: Dec 2014
Posts: 1,715
Likes: 60
From: Central NH
Drop the tank.
Seriously, dropping the tank, even with some gas in it will be easier, quicker and far less damaging to your EX. You can drain the fuel out once it's down (or do some siphoning before you drop it) so it's lighter and easier to handle going back up.
Taking the tank out is an easy job, I've done it twice now and could have it empty and sitting on the ground in about an hour with only a handful of hand tools and a floor jack.
I think it would be more work and time consuming to properly locate, mark, cut, fab a capturing/locating flange and reinstall the cut out section without it looking and performing like a less than perfect option.
Drop the tank.
Seriously, dropping the tank, even with some gas in it will be easier, quicker and far less damaging to your EX. You can drain the fuel out once it's down (or do some siphoning before you drop it) so it's lighter and easier to handle going back up.
Taking the tank out is an easy job, I've done it twice now and could have it empty and sitting on the ground in about an hour with only a handful of hand tools and a floor jack.
I think it would be more work and time consuming to properly locate, mark, cut, fab a capturing/locating flange and reinstall the cut out section without it looking and performing like a less than perfect option.
Drop the tank.
Bingo ! Seriously..... drop the tank. It really isn't that bad.
Fleet Mechanic
Joined: Mar 2004
Posts: 1,483
Likes: 1
From: SE PA
When it was time for my Ex to get a fuel pump, I couldn't get it back in the garage and decided to have a local garage do the pump. I work with a Ford dealer and was able to get a discount on the actual pump module. My friends at the garage suggested I do so.
Anyhow, if memory serves, they changed me about $125 to do the pump. Money well spent in this case....
Anyhow, if memory serves, they changed me about $125 to do the pump. Money well spent in this case....
Post Fiend
Joined: Mar 2002
Posts: 19,402
Likes: 38
From: Bonita Springs FL
Unless you plan on needing to get in there frequently, I can't imagine it's worth the time and effort. Dropping the tank, even by yourself, is not that bad. A floor jack and some scrap wood and you're home free.
Super Moderator
Joined: Aug 2003
Posts: 25,479
Likes: 738
From: Isanti, MN
Agree with the consensus, it's really not a bad job. Four bolts and the tank comes down, just be prepared to handle the weight. With the rear axle on the ground, the tank can come all the way down without breaking the lines IIRC.
Here's my thread on the matter with lots of pics:
https://www.ford-trucks.com/forums/1...s-of-pics.html
Here's my thread on the matter with lots of pics:
https://www.ford-trucks.com/forums/1...s-of-pics.html
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Super Moderator
Joined: May 2004
Posts: 29,380
Likes: 118
From: Central Coast of CA
I'm sorry, this is a lather, rinse, repeat post...just drop the tank, it will be so much easier.
Stewart
Stewart
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Moderator
Joined: Jul 2010
Posts: 12,050
Likes: 1,549
From: Media PA
I had exactly the same issue with mine, original was a California pump assembly with the integrated vapor pressure sensor (that is the extra part) and the first replacement was a non-Cali model without the sensor, just like you got. There should be a sticker on the underside of the hood that denotes if it the EX has Cali emissions or not, my rig is missing that sticker. You will need to trade pumps for the correct model to keep the computer and check engine light happy.
Post Fiend
Joined: Mar 2002
Posts: 19,402
Likes: 38
From: Bonita Springs FL
Does your truck have a glow plug relay or a glow plug control module?