- Joined
- October 20, 2004
- Messages
- 8,984
- Reaction score
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- 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.
Here is the size of cuts i made.
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.
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.
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.
You will now need to replace the interior parts that you removed earlier.
If you have any questions just ask.
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.
Here is the size of cuts i made.
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.
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.
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.
You will now need to replace the interior parts that you removed earlier.
If you have any questions just ask.