Dismiss Notice



Register Today It's free! This box will disappear once registered!

How to: 1st Gen Gas Tank Fuel Pump Access Panel

Discussion in 'Body Work & Detailing' started by Burns, March 17, 2007.

  • Searches ExplorerForum.com
    1. Burns

      Burns Elite Explorer Moderator Emeritus

      Joined:
      October 20, 2004
      Messages:
      9,034
      Likes Received:
      15
      Trophy Points:
      58
      City, State:
      Pulaski, TN
      Year, Model & Trim Level:
      1991 Explorer/2002 F-250
      After a few were talking about the wonderful task of getting the fuel pump and float out of the gas tank in a explorer. I also just love doing this so me and my dad have created a easy solution that we have now used in three of our four first gen explorers. We have cut out the floor above the gas tank and made a access panel to go back on. Here is how you can do this for your self. Do not do this with a full tank of GAS. There is the possibility that you might SLIP. I dont have to tell you what happens when there is sparks and possibilty of gas. You need to be carefull if you attempt to do this project.
      Step 1: Remove you rear seat and peal the carpet back so you can see the most of the floor under the drivers side back seat. Also while working on this project please note: The safe way to do this is to remove the tank before cutting. Its better to be safe now. It may not save you time now but it will save you if you ever have the need again.

      Step 2: Prepare to cut your floor. I used a grinder with a small disk. The best tool for the job would be a dremel. They are small and will allow the margin for error to go nearly to zero.
      [​IMG]
      Here is the size of cuts i made.
      [​IMG]
      After you have made your cuts you may have to use the hammer and bend some of the metal around the edges to ensure that you do not slice you hand open while pulling the sending unit/gas pump unit.

      When you are cutting you need to remember that the gas lines are there. When cutting you only have about a inch and a half of room. Dont go to deep and cut a line.
      [​IMG]


      Step 3: You will now need to prepare to put you truck back into usable order. You will need to make a patch panel to go over the hole that was cut into the floor. You will need to make a few bends in the metal. This can be done with the bare hands. No need for any special benders here. Use a thin sheet metal to make your cover.
      [​IMG]
      Next. You will need to do some drilling. You need to drill some holes to allow you to screw the new panel back to the floor. Silicone will then be added to the floor and the patch panel on top. Screw it down to the floor and you are done.
      [​IMG]

      You will now need to replace the interior parts that you removed earlier.
      If you have any questions just ask.
       
      Last edited: September 23, 2009
    2. Support EF

      Join the Elite Explorers for $20

      Explorer Forum has probably saved you that much already, and will continue to save you money as you learn how to diagnose fix problems yourself, and learn which modifications work without having to experiment on your own. Elite Explorer members see practically no ads, can add their own profile photo, upload photo attachments in all forums, and Media Gallery, create more private Conversations, and more. Join Today. Your support is greatly appreciated.


      to hide adverts.
    3. Phager

      Phager Active Member

      Joined:
      January 29, 2007
      Messages:
      161
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Corvallis, OR
      Year, Model & Trim Level:
      1991 XL
      Thanks Burns. That's a great write up.
       
    4. Gatorblazer

      Gatorblazer Elite Explorer

      Joined:
      March 8, 2006
      Messages:
      794
      Likes Received:
      0
      Trophy Points:
      16
      City, State:
      Moody, AL
      Year, Model & Trim Level:
      02 Explorer, 09 Mazda 5
      where was this thread Thursday when I replaced my fuel pump! Why wasnt I smart enough to figure this out myself!
       
    5. Burns

      Burns Elite Explorer Moderator Emeritus

      Joined:
      October 20, 2004
      Messages:
      9,034
      Likes Received:
      15
      Trophy Points:
      58
      City, State:
      Pulaski, TN
      Year, Model & Trim Level:
      1991 Explorer/2002 F-250
      Its been a life saver for me
       
      • Like Like x 1
    6. james t

      james t moderation Staff Member Moderator Elite Explorer

      Joined:
      January 27, 2002
      Messages:
      10,689
      Likes Received:
      4
      Trophy Points:
      58
      City, State:
      Texarkana AR/TX
      Year, Model & Trim Level:
      94 SAS sport
      Ive done the same on a couple of trucks ive owned. I did it the first time about 10 years ago and ill never drop a gas tank again. :D
       
    7. uh60james

      uh60james Active Member

      Joined:
      February 19, 2006
      Messages:
      274
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Fayetteville, NC
      Year, Model & Trim Level:
      '93 Sport (Dora), '06 XLT
      What is the stuff that you sprayed all over the exposed area of the fuel tank. I see it is rusty in the first pic and then has some tan gunk all over it.
       
    8. blueka

      blueka Elite Pickler Elite Explorer

      Joined:
      December 18, 2005
      Messages:
      4,918
      Likes Received:
      12
      Trophy Points:
      48
      City, State:
      UK
      Year, Model & Trim Level:
      97 UK XL & 99 Sport V8
      when my ex first died (the day after I bought it) the AA diagnosed fuel pump failure.

      I bought a new pump ($500) and a new fuel pump relay ($50) plus crank sensor ($50)

      plus a day's labour ($200) and 2 sets of plugs ($60) only to find out that the timing on the left bank had slipped.. great eh?

      I didn't drop the tank tho.. I didn't know the first thing about explorer's then..

      Si
       
    9. JMan689

      JMan689 Well-Known Member

      Joined:
      August 4, 2006
      Messages:
      1,852
      Likes Received:
      1
      Trophy Points:
      46
      City, State:
      Downers Grove, IL
      Year, Model & Trim Level:
      '14 Focus ST
      Looks like dried mud to me.



      Awesome thinking Burns guess ill work on doing this to both my Xs this spring/summer.
       
    10. gsmaclean

      gsmaclean Active Member

      Joined:
      February 11, 2007
      Messages:
      397
      Likes Received:
      1
      Trophy Points:
      16
      City, State:
      Strongsville, OH
      Year, Model & Trim Level:
      03 Limited
      I did this exact procedure last fall when I replaced my fuel sender - I never saw this thread first, so I ended up doing a lot of measuring before cutting, to make sure I got it right.

      Instead of a grinder/dremel (which make SPARKS, which, to me, is just plain stupid when you're working next to the gas fittings), I used an air chisel. You can get them for under $10 at Harbor Freight, and it cuts through the metal like a knife through butter.

      Also, when I cut the metal to replace, I cleaned it and spray-painted it with some leftover paint I had, to keep it from rusting. Instead of screwing it in place, I used pop-rivets.

      But I can attest that this method works great, and is far easier than dropping the tank.
       
    11. unclemeat

      unclemeat Well-Known Member

      Joined:
      October 20, 2002
      Messages:
      3,082
      Likes Received:
      4
      Trophy Points:
      48
      City, State:
      Richmond, VA
      Year, Model & Trim Level:
      91 sport
      A question, can the repair plate be replaced using a metal bonding epoxy?

      I need to mine soon.
       
    12. Burns

      Burns Elite Explorer Moderator Emeritus

      Joined:
      October 20, 2004
      Messages:
      9,034
      Likes Received:
      15
      Trophy Points:
      58
      City, State:
      Pulaski, TN
      Year, Model & Trim Level:
      1991 Explorer/2002 F-250
      Im sure you can used metal bonding epoxy. I have never used it. I used screws and some rtv to make it seal up for easy removal later.
       
    13. carlover

      carlover Well-Known Member

      Joined:
      July 30, 2005
      Messages:
      3,046
      Likes Received:
      3
      Trophy Points:
      48
      City, State:
      Fontana,CA
      Year, Model & Trim Level:
      '96 XL
      Ok, quick question. Anyone know if the fuel pump is in the same spot on a 96???
       
    14. JMan689

      JMan689 Well-Known Member

      Joined:
      August 4, 2006
      Messages:
      1,852
      Likes Received:
      1
      Trophy Points:
      46
      City, State:
      Downers Grove, IL
      Year, Model & Trim Level:
      '14 Focus ST
      In the tank? Should be
       
    15. carlover

      carlover Well-Known Member

      Joined:
      July 30, 2005
      Messages:
      3,046
      Likes Received:
      3
      Trophy Points:
      48
      City, State:
      Fontana,CA
      Year, Model & Trim Level:
      '96 XL
      To add a little to this thread for us 2nd gen guys. You need to make the opening wider towards the center of the vehicle.

      pump1.jpg

      pump2.jpg
       
      • Like Like x 1
    16. timn8er

      timn8er Member

      Joined:
      February 19, 2008
      Messages:
      59
      Likes Received:
      2
      Trophy Points:
      6
      City, State:
      Oshawa Ontario
      Year, Model & Trim Level:
      1995 Eddie
      Great Idea. I cursed Ford when my pump died. Had to empty a full tank and drop it. Unlike my old VW. open the truck remove the access cover. spin the ring and remove the pump. sweet. It was after i droped the tank I thought that I should have cut a hole, LOL.

      Remember Gas does not burn or ignite.....

      Its the Fumes (Gas+Oxygen)

      Got that wrong on an exam. frigin trick questions..
       
      • Like Like x 1
    17. mikesparky

      mikesparky Active Member

      Joined:
      August 9, 2006
      Messages:
      104
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      WPB, FL / Southern Pines, NC
      Year, Model & Trim Level:
      95 sport OHV
      This is awesome! I was going to drop my tank this weekend, now I'll do this. Can't thank you guys enough.
       
    18. JCUZ

      JCUZ Well-Known Member

      Joined:
      September 4, 2007
      Messages:
      1,253
      Likes Received:
      2
      Trophy Points:
      0
      City, State:
      Canberra, Australia
      Year, Model & Trim Level:
      2004 Explorer Limited V8
      Does that mean if you hold your nose while lighting petrol, it won't ignite?

      Anyone done this on a 3rd Gen yet?
       
    19. Fire926

      Fire926 New Member

      Joined:
      January 9, 2008
      Messages:
      21
      Likes Received:
      1
      Trophy Points:
      0
      City, State:
      Kalamazoo, MI
      Year, Model & Trim Level:
      1994 XL 4x4
      It may sound crazy but you're actually more at risk with a tank not full of fuel since gasoline itself is not what ignites and burns but the vapors right above the liquid do. So a tank 1/2 full is much more dangerous than a full tank. Great post though!
       
      • Like Like x 1
    20. Anime

      Anime EF YEAH!! Elite Explorer

      Joined:
      November 6, 2000
      Messages:
      5,446
      Media:
      9
      Albums:
      1
      Likes Received:
      11
      Trophy Points:
      48
      Year, Model & Trim Level:
      2018 EX Sport Concept
      I prefer to drop the tank when it's time to replace the fuel pump, since by the time it needs to be pulled and replaced, enough junk has probably accumulated on top of and around the tank to justify dropping it to clean the tank, the inside of the left frame rail,and check all the hoses and wires hidden behind the tank. It's also good to remove the bolts holding the tank straps so they don't rust solid to the rather weak threaded clips.
       
    21. Ranger Al

      Ranger Al Active Member

      Joined:
      December 1, 2004
      Messages:
      474
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Fresno, California
      Year, Model & Trim Level:
      '00 FX4 Ranger
      It is called "trap door", we used to have a 75 Toyota Corona and there was a trap door to get to the fuel level sensor. The Japanese beated us to it! lol
       
    22. rookieshooter

      rookieshooter Moderator Emeritus

      Joined:
      March 13, 2005
      Messages:
      7,297
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Martinsburg WV
      Year, Model & Trim Level:
      84 BII "Li'l Samson"
      I've done the same thing to my B2 with the door. Glad I did it too. Had a problem with a new sending unit the same day I installed it in tank. Had it turned 90 degrees the wrong way. Saved a whole bunch of time.
       
    23. Char

      Char Admin's Wife, Explorer Babe Staff Member Elite Explorer

      Joined:
      February 10, 1999
      Messages:
      839
      Likes Received:
      0
      Trophy Points:
      26
      City, State:
      Phoenix, Arizona
      Year, Model & Trim Level:
      1993 Explorer XLT
      I really like the idea of an access cover to get to the fuel pump, but the procedure has me worried...

      If someone has a fuel leak or seapage at the top of the tank grinding directly above it won't be a great idea to say the least. I believe the best way to go about this would be to drop the tank and cut the access hole with the tank removed, or dropped and covered with a spark/flame proof blanket.

      It may not save you the hassle of dropping the tank this time, but it will be there when you may need it the most, like on the trail in the middle of nowhere.
       
    24. Char

      Char Admin's Wife, Explorer Babe Staff Member Elite Explorer

      Joined:
      February 10, 1999
      Messages:
      839
      Likes Received:
      0
      Trophy Points:
      26
      City, State:
      Phoenix, Arizona
      Year, Model & Trim Level:
      1993 Explorer XLT
      Whoops... looks like Char was using my 'puter;)
       
    25. agape

      agape New Member

      Joined:
      January 11, 2008
      Messages:
      2
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Rochester, MN
      Year, Model & Trim Level:
      96XLT
      Tank Access Panel

      Just found your post on the cutting of the access panel.
      I have already taken the skid plate off, disconnected the fuel fill lines on my son's 96 explorer but not very good with cutting metal.
      I am working with the instructions which I found on this site contributed by Gregory B. entitled "Fuel Pump Removal and Installation 1995-2001 Explorer." The next step he says is to disconnect the lines at the pump. Could you tell me what specific fuel line tool is needed to disconnect the lines at the pump. Also can the tank be lowered a little to provide better access to those connections? If I knew how to contact Gregory B. I would ask him, but thought you might be able/willing to respond. Any help you can give this 72 year old "shade tree mechanic" will be greatly appreciated.
       
    26. Willard

      Willard Well-Known Member

      Joined:
      March 16, 2007
      Messages:
      3,192
      Likes Received:
      1
      Trophy Points:
      46
      City, State:
      Bloomington, Indiana
      Year, Model & Trim Level:
      04 Ranger Edge
      Yea, I agree about that with leaking gas. That's a problem I have, it leaks gas, so I know I will have to drop the tank. I'm not grinding anything right above a gas leak :eek:
       

    Share This Page







    We Support Our Troops!