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Stock 2002 - 2005 Explorers Questions related to non-modified 2002 - 2005 Explorers and Mountaineers. Sport Trac and Sport use the 1995-2001 forum.

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Old 07-03-2007, 07:07 PM   #1
SyberTiger
Orlando
2002 Limited 4x4
 
Join Date: May 2007
Posts: 95

Vehicle Specs

Changing fuel filter on third generation X

I just changed out my fuel filter on my 2002 Explorer. It was a beatch in a sense because I had never changed out a fuel filter with the two different types of clips used on either end of the filter. Thus, I didn't possess expert level experience doing the proceedure. It took me two hours to change it out when a more reasonable figure (if you know what you are doing and have the proper tools) is 30 minutes. I thought I'd take the time here to expand on what some others have said about the proceedure as well as what I learned. It seems that a lot has been said but no one really has put it all together with a more detailed explanation for the third generation Explorers. So here's my take. I am not a mechanic nor do I play one on TV nor do I posess professional training on the subject matter so I assume no liability for death, dismemberment, injury, or damage to you or your vehicle so use this proceedure at your own risk!

1. Do not change the fuel filter with the truck engine or exhaust hot. Change it with the engine cool and exhaust cool. To maximize your working area drive the front wheels of the Explorer onto ramps. This should be the only driving you do from a cold start. It is a good idea to perform this proceedure outside with good ventilation.

2. Relieve fuel pressure in the system before attempting to remove the fuel filter. This will minimize the chance of a gasoline bath or being blinded by spraying fuel. On the 2002 Explorer (third generation) the fuel pump can be disabled by removing the fuel pump's associated relay. The relay is located in the fuse and relay black box located in the engine compartment on the drivers side and near the firewall. Open the box and remove relay #48. Double check your owner's manual if you do not have a 2002 Explorer in case of numbering differences. Start the Explorer and let it run out of fuel. Attempt to start it a couple of more times to insure the fuel system is no longer pressurized.

3. The fuel filter is located on the passenger side in front of the fuel tank. This puts it approximately under where the passengers butt would be. If you look in front of the fuel tank closely you will see two fuel lines clipped to one side of the filter but its hard to see because of the heat sheild and plastic cover over the fuel filter.

4. There is an aluminum heat shield in a vertical position that is located between the passenger side exhaust pipe (I have a V-8 engine) and the fuel filter. This helps block some of the heat from the exhaust pipe to the fuel filter and tank. The heat shield is held on by three 13mm bolts. Remove them, they are easy to get to and remove. Take the aluminum heat shield off.

5. Once the heat shield is removed you will see a plastic shield covering the fuel filter. It is held on by two 10mm bolts. Remove them, they are easy to get to and remove. Take the plastic cover off. You will now see the entire fuel filter and the three lines going in/out the filter.

6. Working on the end of the fuel filter with only one in/out line. Follow the proceedure outlined in the pictoral description seen here: http://www.explorerforum.com/forums/...d.php?t=102197 Be carefull because even though pressure has been relieved you will still get a trickle of fuel when the line is removed. It is best to have a pan to catch the fuel. There has been a lot of discussion regarding the fuel line removal tool used. Some people feel the metal (two half circle scissor action) type is better while some feel the plastic tool pictured is better. Before changing out my filter I purchased both types in case I had a problem. My expectation was that the plastic version would work better so I tried that one first without any success. The plastic wasn't rigid enough considering the pressure I had to put on it to slide it in. I then tried the metal scissor type and it worked fine. Keep in mind taking off this side with the clip still isn't a cakewalk. I have big hands and there is limited room. You need to be able to work the tool as outlined in the link above thus it can take some effort to make it work.

7. The other side of the fuel filter has two in/out lines attached in a different manner than the side already discussed. The two line side uses red plastic clips to hold the couplers onto the filter connections. The clips DO NOT necessary just unclip then you go happily on your way to replacing the filter. It was this side that caused the most grief for me as I did not completely understand nor visualize how the clips work. You will want to make sure the clip is pointing toward you (down) with the red portion fully toward you. You will notice ridges on a major portion of the clip that look like they are there so your thumb doesn't slip off. This ridged area clips onto the other side of the red area. In other words, the red area is essentially two sides that clip together. The "ridged" side hinges on the side where it appears to make contact with the black plastic portion of the coupling. To unclip this you may try using enough finger force to push down on the small "no-ridged" side while pulling up on the ridged side, allowing the ridged side to hinge outward. Since my hands are too big I used a small flat head screw driver to gently "unclip" the clips. This is done by pushing the screw driver head into the area where it appears the ridged area meets the other side. By pushing into what appears to be a slotted area "in the middle of the red clip" then pulling outward on the rigged side the clip with hinge out. NOTE, you will STILL NOT be able to remove the fuel line coupling off the filter. You have to do one more thing with the red clip to make sure it isn't preventing sliding of the coupling off the filter. With the red clip "unclipped" such that the ridged area is hinged outward you need to push both sides of the red area towards the other side of the black coupler. In other words, the red clip is not molded or permanently snapped onto the black portion. It actually slides to the other side of the black plastic. If the red portion was facing down towards you when you started this proceedure then this means you need to push on both sides of the red clip (after doing the "unclipping" portion describe above) upward toward the sky to get it to slide. Just use enough finger force and it should slide. Again, make sure you have slid both the left and right half of the red clip. Now, perform the same proceedure on the other in/out line. Again, watch out for fuel drips. The filter is full of fuel and may empty on your head if you are not careful.

8. Now, with the fuel in/out lines removed take out the entire fuel filter with bracket out (the bracket was unscrewed in the same proceedure that removed the black plastic cover). Make a note of how the old filter is mounted to the bracket because when you slide in the new filter you will want to make sure it is rotated in the same position to make it easier when you reconnect the fuel lines. Using considerable force, slide the bracket off the old filter. I used a hammer and gently tapped the old filter to get it off the bracket. There actually is a fair amount of spring tension in the bracket grabbing onto the filter. Once the bracket is off you should be able to use hand force to get the new filter on.

9. From here it should be clear how to perform the proceedure in reverse to get everything buttoned back up. NOTE, you will NOT need the fuel line removal tool to reconnect any of the lines. The lines just slide on. Make sure both ends are clipped properly like you found them with the old filter. Once you get everything back together don't forget to put the fuel pump relay back in.

If I goofed anywhere in here please let me know and I will correct the descrepancy. Thank you for listening and good luck with your fuel filter.

p.s. I now know why I didn't change my fuel filter until it had 82,000 miles on it... ...yup, stupid on the one hand but apparently I put off some grief for a number of years. I guess I've been burning some pretty clean fuel to date, huh?




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Last edited by SyberTiger; 07-03-2007 at 07:21 PM.
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Old 07-04-2007, 03:27 PM   #2
Yamvip
Swanton, Ohio
2002 XLT 4x4 4.0L FFV
 
Join Date: Mar 2006
Posts: 126

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Pretty well detailed, i believe.I need to get the ball roling and change mine out also!!
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Old 06-03-2008, 06:25 PM   #3
turblown
Phoenix, AZ
2003
 
Join Date: Feb 2008
Posts: 4

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Smile

Quote:
Originally Posted by SyberTiger View Post
My expectation was that the plastic version would work better so I tried that one first without any success. The plastic wasn't rigid enough considering the pressure I had to put on it to slide it in. I then tried the metal scissor type and it worked fine.
Thank you for this post! I tried to change my fuel filter using the plastic disconnect tool for like 2 hours. I thought I was doing something wrong. So I researched it, found this post, bought a metal disconnect tool and the fuel line was off in like 10 seconds! Woo Hoo!
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Old 06-14-2008, 07:21 PM   #4
sethmorgan
Hanahan, SC
2002 XLT 4.0
 
Join Date: Jan 2008
Posts: 71

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I just replaced mine with help from this post and I couldn't get the exit line off with the plastic tool either. The aluminum one got it off in about 5 seconds. BTW, replacing the fuel filter eliminated the shimmy and shakes at idle.
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Old 07-08-2008, 09:10 PM   #5
lrm
2002 Mercury Mountaineer
 
Join Date: Jun 2006
Posts: 23

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Filter outlet hose won't budge

2002 Mountaineer with 4.6 L V8. I'm replacing my fuel filter, I've got over 100K miles.

I've fought this thing for 2 days when I have time and the clip comes off using the tool, plastic one was no good, metal one took the prying I had to put on it. I pull and twist and can't get the fuel outlet line off the filter. I have given up a few times and pushed the outlet line to get it back in place and I hear the click of the clips seating back on the filter so I know I'm getting the clips out of the way. The thing won't slide off the fuel line. I can turn the filter on the fuel hose, it's not locked on. I'm thinking the clips that are supposed to release from the lip of the filter outlet are somehow imbedding into the filter line.

I don't have any jiggle room in the connector to move it towards the filter. The new sticky illustrates a 1-2-3 motion to get the clips to disengage using the tool and there's no movement at all towards the filter.

Any ideas on what to do to get the fuel out line off of the filter?

Last edited by lrm; 07-08-2008 at 09:55 PM.
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Old 07-08-2008, 11:11 PM   #6
justchecking
Lebanon, Ohio
2002 XLT V6 2WD
 
Join Date: Apr 2008
Posts: 93

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I fought with mine for some time also using the metal tool.

What I finally did was take a pair of pliers with a rubber coated handle and wedge one end of the handle between the filter and the tool. The tip of the handle was against the filter and the curve of the handle was against the tool. I pried agaisnt the tool a bit and could here the clips opening up. A little more force, and it popped right off. That took about 5 seconds, after having spent 20 minutes with just my fingers...




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Old 07-09-2008, 01:17 AM   #7
Rebelord
Az
2003 Eddie Bauer
 
Join Date: Jul 2008
Posts: 6

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Yea, I just changed mine the other day. Its a PIA for sure. Used a metal tool and still kicked my but. But 79k and it was probally the original one. BTW, when it did finally come off, I smacked my hand on the undercarraige.

Ski




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Old 07-09-2008, 11:22 AM   #8
SyberTiger
Orlando
2002 Limited 4x4
 
Join Date: May 2007
Posts: 95

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Quote:
Originally Posted by lrm View Post
I don't have any jiggle room in the connector to move it towards the filter. The new sticky illustrates a 1-2-3 motion to get the clips to disengage using the tool and there's no movement at all towards the filter.

Any ideas on what to do to get the fuel out line off of the filter?
IMHO, I think the clips are partially disengaged...enough such that when you push the filter all the way back on you hear the "click". I'd keep doing what you are doing with the metal removal tool...just make sure you keep pushing that metal tool in further. Another hint...while you are pushing the metal tool in you need to push on the filter towards the metal tool otherwise all you are doing in creating a lot of pressure on the tabs of the metal clips as you slide that metal removal tool. To reiterate...push on the filter towards the fuel line AND push the fuel line towards the filter AND at the same time push that metal removal tool towards the filter. Seems like we could always use a third hand and more working area but you got what you got so you're gonna need to do the best you can.

Good luck...keep in mind that with the metal removal tool it is still a PITA. You may have given up because you thought it would be easier and just as you almost had it unclipped you stopped because you were thinking you must be doing something wrong.




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Old 07-09-2008, 04:50 PM   #9
lrm
2002 Mercury Mountaineer
 
Join Date: Jun 2006
Posts: 23

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Metal vs. Plastic tool

I gave up on the plastic (rubber) tool because it didn't seem to open the clips wide enough. I thought it was collapsing and not getting the clips open enough. The metal one has marks on it from where it was rubbing the clips so I know it was getting to them. I was wondering if the rubber in the hose connector has fused to the fuel filter line and spraying wd40 into the fitting would penetrate in there and loosen it? Would they have put an adhesive in there to seal it tight?

It seems like it needs a redesign, add extra hose that Ford wouldn't spend $1.50 on to put it in there right or make it so you can swing it lower so you can reach it. This should be easier. I was considering cutting off the filter and cutting the old filter line out of there one little piece at a time to get it out of there but reconsidered. I thought if I could collapse the tube and crush it maybe it would come out. Last resort and big mess if it didn't work.

Now I have to try it one more time. Every time I read the posts on here I get encouraged to give it another go. I much appreciate the help sybertiger, and all who contribute.
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Old 04-10-2009, 12:59 PM   #10
Recoil Rob
2002 XLT
 
Join Date: Apr 2008
Posts: 21

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Anyone have the part number of the metal tool and a source or do I have to go to Ford?
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Old 04-10-2009, 07:02 PM   #11
gnzth01
North Mankato, MN
'04 XLT 4x4
 
Join Date: Sep 2008
Posts: 33

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Don't have a part number, but Advance auto has a whole section of disconnect tools.




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Old 04-10-2009, 07:30 PM   #12
Swamp Fox
SC
'04 XLT 4WD
 
Join Date: Mar 2009
Posts: 37

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I bought the metal scissor tool at NAPA. I had to use a flathead screwdriver with it to get the tool to spread away from the filter and push the tool in to disconnect from the fitting. I think I could do the whole thing fairly quickly the next time.
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Old 04-11-2009, 11:08 AM   #13
Recoil Rob
2002 XLT
 
Join Date: Apr 2008
Posts: 21

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Does the metal one look like the blue plastic one in the above tutorials? Can't find anything to fit the description at Advanced auto.
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Old 04-12-2009, 07:31 AM   #14
Swamp Fox
SC
'04 XLT 4WD
 
Join Date: Mar 2009
Posts: 37

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Hey Recoil Rob check this link out.

http://shop.advanceautoparts.com/web..._disconnect___

If the link doesn't work do a search for "disconnect" on the Advance Auto Parts website. When you see the results the have a set at the top. The metal one is the second from the right. They also have a tool without a picture at the bottom of the list of results. I think that's the metal one. All I know is they do carry it. Just ask. Good luck.
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Old 04-12-2009, 11:40 AM   #15
Recoil Rob
2002 XLT
 
Join Date: Apr 2008
Posts: 21

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Thanks Fox.
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Old 04-22-2009, 07:50 PM   #16
cyress
Sudbury, Ontario
04 Explorer LTD V8 4x4
 
Join Date: Mar 2009
Posts: 53

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I will be changing my filter and also taking pics. With all this chatting..someone should of taken pics. Now all i got to do is find where my filter is..lol
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Old 08-13-2009, 05:00 PM   #17
expl03100k+
2003 XLS
 
Join Date: Aug 2009
Posts: 3

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I can't remove the plastic clips

Can somebody help me out here, not sure how to remove the plastic clip

see picture
http://www.flickr.com/photos/aornelas/3817957795/
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Old 08-14-2009, 09:01 AM   #18
sethmorgan
Hanahan, SC
2002 XLT 4.0
 
Join Date: Jan 2008
Posts: 71

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Quote:
Originally Posted by expl03100k+ View Post
Can somebody help me out here, not sure how to remove the plastic clip

see picture
http://www.flickr.com/photos/aornelas/3817957795/
On that type, I'm pretty sure once you disengage the clip like in the first picture, you push it up and away from you (from your perspective as the photographer in that shot). It doesn't come completely off, but the clip is out of the way for the line to separate from the filter. HTH.
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Old 08-17-2009, 10:14 PM   #19
extremeclosings
 
Join Date: Aug 2009
Posts: 1

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I got the answer for your fuel filter problems!!!

When you go to put the special metal tool...no, do not use the plastic tool...use the metal one....what you do is you press the metal tool into the clasp...press them together real hard and the fuel line will pop off. Now...fo thte hard part....when you unhook the red clasps...yes it is a clasp...unook it, and than press the little clasp at the toher end towards the other end of the line...it will than be pushed back and you will have to jiggle the line off....repeat this with the other line as well. Easy? Try it....
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