Fuel Filter Replacement w/pics

muzzymaniac · 11-01-2007, 12:58 PM

I found there was no How-To on fuel filter replacement on this site so I thought I'd add one. I just got done with it so here it goes:

First off, this was done on my 04 Explorer 4.0l with 29k on it. I've been suffering from the shakes at idle. It seemed to happen after getting gas at Delta Sonic.

Your experience may be different depending on model and year.

Tools:

ratchet
10mm socket
13mm socket
Ford fuel tool
rags
new filter
safety glasses

Step 1:
Pull fuel pump relay #48 and start truck. Truck may run and stall or not run at all.

#2
Block rear wheels and raise front end. Only the passenger side is really necessary. USE JACK STANDS

#3
Locate filter. It's on the passenger side at the front/top of the fuel tank. It has a plastic cover then an aluminum heat shield over it so you won't see it.

#4 remove heat shield. Held on by 3 13mm bolts
heat shield

#5 Remove plastic cover. Held by 2 10mm bolts
Plastic cover

Now you can see the filter.

#6
Remove the hose connections. The output side has a funky metal clip that needs to be slide towards the filter a bit then pushed up to disengage. Use the Ford tool to remove the output side hose. This goes over the filter tube and slide under the hose connection. You'll have to play with it a bit but the basic idea is to slide the tool under the fuel line connection releasing the internal spring and it'll pop apart. This is not fun since there is little room and you are on your back. The input side of the filter uses a different connector. It has a red plastic clip that needs to be undone. It's similar to the plug wire guides. I used nothing more than my hands. Once open gently push the 2 ends up to release the filter. It's kinda like a upside down U.

You know those black caps that are on the end of your new filter? They're great for capping the old filter while your working on it.

Ford Tool

#7 remove filter from bracket
Don't try pulling it out - that sucker is really in there. I used a rubber mallet to tap the filter out.

REMEMBER THIS IS A GAS FILTER - DON'T USE A REGULAR HAMMER!!! Use a block of wood if you have to.

#8 install new filter.
I put a light coating of grease on the new filter to help slide it back in. Should help with removal next time too. Make sure you have the filter in the right direction.

Filter in bracket

Reattach fuel lines. No biggie here - just reverse of removal.

Now is a good time for anti-seize on the bolts for next time.

Put the cover and heat shield back on.

Replace relay

Start truck and check for leaks.

Now here's the kicker. The truck ran beautifully! I only let it run long enough to check for leaks but there were no shakes!
Then I did what I always do to feel better about the busted knuckles and hard work I just put in - I poured the contents into a water bottle...

Damn! That's nasty! Remember I've only got 29k on my girl. How many do you have and when was the last filter change?? Go out and do it now!

EasyRhino · 11-01-2007, 11:10 PM

That's great! Very helpful, guess I need to do mine since it is original at 86K miles

Perhaps this write up w/ pics should be flagged on the web site???

**BrooklynBay** · 11-01-2007, 11:28 PM

Excellent thread! There is a similar one in the site's list of useful threads, but it is for older generation Explorers. Could a moderator correct the spelling of the title of this thread so that if somebody does a search it will come up?

muzzymaniac · 11-02-2007, 09:58 AM

Thanks guys. I guess I really botched the title up! LOL!!! Mods - Please help with that.

**BrooklynBay** · 11-02-2007, 09:59 AM

You could PM any Mod to fix it for you.

**Ray Lobato** · 11-06-2007, 11:25 PM

Nice Writeup!

I think I'll make it a sticky.
Oh and I fixed your typo.

muzzymaniac · 11-08-2007, 10:02 AM

Quote:

Originally Posted by BrooklynBay

Excellent thread! There is a similar one in the site's list of useful threads, but it is for older generation Explorers. Could a moderator correct the spelling of the title of this thread so that if somebody does a search it will come up?

I didn't see one in there. Maybe one day my thread will grow up and get a membership there.

SyberTiger · 11-08-2007, 04:59 PM

What about this thread:

CHANGING FUEL FILTER ON THIRD GENERATION X

**BrooklynBay** · 11-08-2007, 08:12 PM

http://www.explorerforum.com/forums/...d.php?t=102197

muzzymaniac · 11-08-2007, 08:57 PM

Quote:

Originally Posted by BrooklynBay

http://www.explorerforum.com/forums/...d.php?t=102197

Ahhh, I was looking in the "how To" section!

**BrooklynBay** · 11-08-2007, 09:02 PM

I was looking in the Useful Threads section, but it was in the General Explorations section.

tmoran93 · 11-25-2007, 12:45 PM

is there any substitute for the fuel filter removal tool?

aldive · 11-25-2007, 12:50 PM

Quote:

Originally Posted by tmoran93

is there any substitute for the fuel filter removal tool?

Not really, however, there are different variations of the tool.

dtholmanmax · 12-04-2007, 10:15 PM

Where can I get one of these filter removal tools. Should I get one at the ford dealer or can it be purchased at Autozone or somesuch?

**BrooklynBay** · 12-04-2007, 10:17 PM

Autozone has them. You could also get them from WWW.Eppys.Com.

trucku · 12-06-2007, 07:45 PM

Excellent!

N182NS · 12-15-2007, 05:03 PM

I just changed mine on 2002 xlt. It has three lines, one is a return line. Excellent article and pictures. Nick

**BrooklynBay** · 12-15-2007, 10:44 PM

Three lines? The filter has 2 sides. One side is in while the other side is out.

N182NS · 12-17-2007, 12:42 PM

Yes it has three lines two on the passenger side one on the drivers side.

Nick

**BrooklynBay** · 12-17-2007, 11:09 PM

What's the third line for?

11-01-2007, 12:58 PM	#1
muzzymaniac Wannabe Elite Explorer Kent, NY 04 Explorer XLT 4.0L Join Date: Sep 2007 Posts: 443 Vehicle Specs (Original Poster)	Fuel Filter Replacement w/pics I found there was no How-To on fuel filter replacement on this site so I thought I'd add one. I just got done with it so here it goes: First off, this was done on my 04 Explorer 4.0l with 29k on it. I've been suffering from the shakes at idle. It seemed to happen after getting gas at Delta Sonic. Your experience may be different depending on model and year. Tools: ratchet 10mm socket 13mm socket Ford fuel tool rags new filter safety glasses Step 1: Pull fuel pump relay #48 and start truck. Truck may run and stall or not run at all. #2 Block rear wheels and raise front end. Only the passenger side is really necessary. USE JACK STANDS #3 Locate filter. It's on the passenger side at the front/top of the fuel tank. It has a plastic cover then an aluminum heat shield over it so you won't see it. #4 remove heat shield. Held on by 3 13mm bolts heat shield #5 Remove plastic cover. Held by 2 10mm bolts Plastic cover Now you can see the filter. #6 Remove the hose connections. The output side has a funky metal clip that needs to be slide towards the filter a bit then pushed up to disengage. Use the Ford tool to remove the output side hose. This goes over the filter tube and slide under the hose connection. You'll have to play with it a bit but the basic idea is to slide the tool under the fuel line connection releasing the internal spring and it'll pop apart. This is not fun since there is little room and you are on your back. The input side of the filter uses a different connector. It has a red plastic clip that needs to be undone. It's similar to the plug wire guides. I used nothing more than my hands. Once open gently push the 2 ends up to release the filter. It's kinda like a upside down U. You know those black caps that are on the end of your new filter? They're great for capping the old filter while your working on it. Ford Tool #7 remove filter from bracket Don't try pulling it out - that sucker is really in there. I used a rubber mallet to tap the filter out. REMEMBER THIS IS A GAS FILTER - DON'T USE A REGULAR HAMMER!!! Use a block of wood if you have to. #8 install new filter. I put a light coating of grease on the new filter to help slide it back in. Should help with removal next time too. Make sure you have the filter in the right direction. Filter in bracket Reattach fuel lines. No biggie here - just reverse of removal. Now is a good time for anti-seize on the bolts for next time. Put the cover and heat shield back on. Replace relay Start truck and check for leaks. Now here's the kicker. The truck ran beautifully! I only let it run long enough to check for leaks but there were no shakes! Then I did what I always do to feel better about the busted knuckles and hard work I just put in - I poured the contents into a water bottle... Damn! That's nasty! Remember I've only got 29k on my girl. How many do you have and when was the last filter change?? Go out and do it now!

11-08-2007, 08:12 PM	#9
BrooklynBay Aerostar Forum Moderator Brooklyn, NY 88 89 93 95 96 Aerostars Join Date: Nov 2005 Posts: 45,810 Vehicle Specs	http://www.explorerforum.com/forums/...d.php?t=102197 __________________ My list of useful threads. My photo gallery. My product reviews. My list of items for sale. Aerostar owners thread. Aerostar parts work in Explorers, Rangers, and Bronco II thread. History of the Aerostar thread. Aerostar Forum. New Members Forum. Ford/Lincoln/Mercury Forum.

11-08-2007, 09:02 PM	#11
BrooklynBay Aerostar Forum Moderator Brooklyn, NY 88 89 93 95 96 Aerostars Join Date: Nov 2005 Posts: 45,810 Vehicle Specs	I was looking in the Useful Threads section, but it was in the General Explorations section. __________________ My list of useful threads. My photo gallery. My product reviews. My list of items for sale. Aerostar owners thread. Aerostar parts work in Explorers, Rangers, and Bronco II thread. History of the Aerostar thread. Aerostar Forum. New Members Forum. Ford/Lincoln/Mercury Forum.

12-04-2007, 10:17 PM	#15
BrooklynBay Aerostar Forum Moderator Brooklyn, NY 88 89 93 95 96 Aerostars Join Date: Nov 2005 Posts: 45,810 Vehicle Specs	Autozone has them. You could also get them from WWW.Eppys.Com. __________________ My list of useful threads. My photo gallery. My product reviews. My list of items for sale. Aerostar owners thread. Aerostar parts work in Explorers, Rangers, and Bronco II thread. History of the Aerostar thread. Aerostar Forum. New Members Forum. Ford/Lincoln/Mercury Forum.

12-06-2007, 07:45 PM	#16
trucku Wannabe Elite Explorer Queens, New York and living in Budd Lake, NJ now. 2002 Explorer XLS 4.0 4x4 Join Date: Jan 2005 Posts: 2,052 Vehicle Specs	Excellent! __________________ 2002 XLS 4.0 SOHC 4x4. Frantz Bypass filter, Mobil 1 5W30.Perma-cool dual remote (2 full flow PureOne PL30001). Perma-cool remote transmission filter (Pure One PL30001). Scanguage II, Sunpro Oil Pressure Guage Gen 4 mirrors "The More Complex The Mind, The Greater The Need For The Simplicity Of Play"

11-01-2007, 11:10 PM	#2
EasyRhino Wannabe Elite Explorer Kailua, Hawai'i '02 Limited 4.6L 4x4 Join Date: Mar 2001 Posts: 1,022 Vehicle Specs	That's great! Very helpful, guess I need to do mine since it is original at 86K miles Perhaps this write up w/ pics should be flagged on the web site??? __________________ Wife's: '02 Limited 4.6L/4x4 Mine: '04 Mustang GT Vert, 2006 C6 Corvette Coupe

11-01-2007, 11:28 PM	#3
BrooklynBay Aerostar Forum Moderator Brooklyn, NY 88 89 93 95 96 Aerostars Join Date: Nov 2005 Posts: 45,810 Vehicle Specs	Excellent thread! There is a similar one in the site's list of useful threads, but it is for older generation Explorers. Could a moderator correct the spelling of the title of this thread so that if somebody does a search it will come up? __________________ My list of useful threads. My photo gallery. My product reviews. My list of items for sale. Aerostar owners thread. Aerostar parts work in Explorers, Rangers, and Bronco II thread. History of the Aerostar thread. Aerostar Forum. New Members Forum. Ford/Lincoln/Mercury Forum.

11-02-2007, 09:58 AM	#4
muzzymaniac Wannabe Elite Explorer Kent, NY 04 Explorer XLT 4.0L Join Date: Sep 2007 Posts: 443 Vehicle Specs (Original Poster)	Thanks guys. I guess I really botched the title up! LOL!!! Mods - Please help with that.

11-02-2007, 09:59 AM	#5
BrooklynBay Aerostar Forum Moderator Brooklyn, NY 88 89 93 95 96 Aerostars Join Date: Nov 2005 Posts: 45,810 Vehicle Specs	You could PM any Mod to fix it for you. __________________ My list of useful threads. My photo gallery. My product reviews. My list of items for sale. Aerostar owners thread. Aerostar parts work in Explorers, Rangers, and Bronco II thread. History of the Aerostar thread. Aerostar Forum. New Members Forum. Ford/Lincoln/Mercury Forum.

11-06-2007, 11:25 PM	#6
Ray Lobato Moderator Join Date: Feb 1999 Posts: 4,649 Vehicle Specs	Nice Writeup! I think I'll make it a sticky. Oh and I fixed your typo. __________________ Happy Wheelin' Ray L.

11-08-2007, 04:59 PM	#8
SyberTiger Wannabe Elite Explorer Orlando 2002 Limited 4x4 Join Date: May 2007 Posts: 319 Vehicle Specs	What about this thread: CHANGING FUEL FILTER ON THIRD GENERATION X __________________ 2002 Ford Explorer 4x4 Limited P275/45R20 on 20" Rims

11-25-2007, 12:45 PM	#12
tmoran93 Wannabe Elite Explorer Boston, MA '03 LTD Join Date: Nov 2007 Posts: 3 Vehicle Specs	is there any substitute for the fuel filter removal tool?

12-04-2007, 10:15 PM	#14
dtholmanmax Wannabe Elite Explorer Dallas, TX 2005 Explorer XLT Join Date: Sep 2006 Posts: 179 Vehicle Specs	Where can I get one of these filter removal tools. Should I get one at the ford dealer or can it be purchased at Autozone or somesuch?

12-15-2007, 05:03 PM	#17
N182NS Wannabe Elite Explorer Metairie, La. 70003 96 XLT Join Date: Dec 2006 Posts: 13 Vehicle Specs	Fuel Filter replacement I just changed mine on 2002 xlt. It has three lines, one is a return line. Excellent article and pictures. Nick

12-15-2007, 10:44 PM	#18
BrooklynBay Aerostar Forum Moderator Brooklyn, NY 88 89 93 95 96 Aerostars Join Date: Nov 2005 Posts: 45,810 Vehicle Specs	Three lines? The filter has 2 sides. One side is in while the other side is out. __________________ My list of useful threads. My photo gallery. My product reviews. My list of items for sale. Aerostar owners thread. Aerostar parts work in Explorers, Rangers, and Bronco II thread. History of the Aerostar thread. Aerostar Forum. New Members Forum. Ford/Lincoln/Mercury Forum.

12-17-2007, 12:42 PM	#19
N182NS Wannabe Elite Explorer Metairie, La. 70003 96 XLT Join Date: Dec 2006 Posts: 13 Vehicle Specs	Three lines Yes it has three lines two on the passenger side one on the drivers side. Nick

12-17-2007, 11:09 PM	#20
BrooklynBay Aerostar Forum Moderator Brooklyn, NY 88 89 93 95 96 Aerostars Join Date: Nov 2005 Posts: 45,810 Vehicle Specs	What's the third line for? __________________ My list of useful threads. My photo gallery. My product reviews. My list of items for sale. Aerostar owners thread. Aerostar parts work in Explorers, Rangers, and Bronco II thread. History of the Aerostar thread. Aerostar Forum. New Members Forum. Ford/Lincoln/Mercury Forum.