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

[rookieshooter]

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.

 

[Char]

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.

 

[Char]

Whoops... looks like Char was using my 'puter

 

[agape]

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.

 

[Willard]

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.

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

 

[ChriszTruck]

I think I'm going to give this a shot when I get the pump. I seriously don't feel like dropping a tank in this f'ing heat, and I see a lot of rusty bolts under there that look like they'd snap. Great thread!

 

[ChriszTruck]

I think I'm going to give this a shot when I get the pump. I seriously don't feel like dropping a tank in this f'ing heat, and I see a lot of rusty bolts under there that look like they'd snap. Great thread!

I cut the floor, and I had some issues with the wrong pump, but the X is running once again. I will be posting a tech write-up on cutting the floor open to replace the fuel pump within a week. I have many photos, and I'm basically going to give a step-by-step account for future use. Thanks to all who have posted such useful information on fuel pump replacement.

This was the most "interesting" part of the process....

 

[hate city]

thanks for the pics, really helped a lot. mine's a '96 but same procedure.

 

[TJTrucker]

Yup, I'm going to cheasle me a hole in that floor tomorrow, this marks the second time i've had to drop that darn tank in less than 6 months. My wife's little 92 Ford Escort wagon has a nice little removeable panel over her gas tank. Already had to change her fuel pump, took about 15 minutes and that includes taking the bottom of the back seat out. Plush two little clips the seat bottom pops right out, four screws and walla there's the top of her gas tank. Now Ford thought of this on the Escorts, why didn't they do it with the Explorer's? Hey there's a lot more money involved with an Explorer compared to an Escort.

Nice post guys, hey has anyone had to cut off those cuplers for the hoses on the fuel tanks. I've got one that's leaking on the high side. Of course the dealer has some mickey mouse kit to repair kit they want $40 for, but I was thinking of cutting the coupler off the hose and then slit the braided line right over the hose fitting on the tank and double clamp it with two of those little stainless steel hose clamps.
Any thought good, bad or otherwise?

 

[malito58]

i thank you so much for this idea being that i dont have a great deal of $ to do this

 

[sksemke]

96 4 door

WIll this procedure work with a 96 xlt 4 door? Also any special tools needed to remove the back seat? Thanks!!!!!!

 

[malito58]

gas tank acces

dear sksemke it works for your 96 and yes you have to remove the small folding seat,as for tools i went the hard way but it worked(i used a chisel and a big hammer) just have in mind to cut near the seat bolt anker(like a half inchor so closer than the diagram posted.other than that you shoud be done very quick and remember to test the fix before you close everything down.it saves you $ and time good luck.
sinc,marcial(malito58)

 

[sksemke]

Done!!

Removed the seat and cut the access panel using a dremel with a cut-off wheel, took about 15mins to cut the hatch. The only problem I had was one of the wires was conected to the top of the tank, I have no idea what it was for but in my effort to try and remove the plug I broke the unit it plugs into off the tank. Like I said I have no idea what it is for but I just plugged the plug into the broken piece and tried to start it and it fired right up!! I would appreciate it if someone could tell me what its for, I thought maybe it might be for the fuel gage but I dont think so. One more note, the bolts holding the seat in were extremely tight, I suggest soaking with WD40 over night. Thanks for all the great posts!

 

[malito58]

wires

congrats sksemke you got it done ,as far as for the wires well the 4wires that goes to the conector are for the pump and gas level the wires coming out from the top are for the evap system,make sure you got them in the right place and mke them water tight(some silicone or grease around them will work besides that you are set,iam glad i was of help,keep the xlt goin!
sinc,malit58(marcial)

 

[gsmaclean]

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

Yes, my 1982 Datsun 200SX had a small panel in the trunk with screws around the outside. You removed the screws, pulled the panel up, and you had access to the fuel sender on the top of the tank.

 

[gsmaclean]

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.

Read my post above - I agree with you, which is why I used an air chisel. It cut through the metal in seconds, and no sparks.

 

[gsmaclean]

Nice post guys, hey has anyone had to cut off those cuplers for the hoses on the fuel tanks. I've got one that's leaking on the high side. Of course the dealer has some mickey mouse kit to repair kit they want $40 for, but I was thinking of cutting the coupler off the hose and then slit the braided line right over the hose fitting on the tank and double clamp it with two of those little stainless steel hose clamps.
Any thought good, bad or otherwise?

The couplers were seized on mine when I opened them up. I ended up cutting through the tubes that connected them to the sender, then jamming a drill into the end and drilling out the tubes from the couplers. I then ripped out the small metal clips inside the couplers with some needlenose pliers, and replaced them with new clips I got at NAPA - they were a couple dollars.

 

[BrooklynBay]

There is an access panel in the front to get to the top of the transmission. I don't know why Ford couldn't put the same type of access panel in the rear over the sending unit? Some foreign vehicles come with access panels in this area.

 

[scrivyscriv]

Will someone post a more specifically worded description or a wide shot photo of where this sweet access door is in context of the rest of the vehicle's interior? I read through the whole thread and have a good idea of where, and can obviously get under the vehicle and see exactly where to cut, but for any future explorer owners it'd be a great reference.

 

[Noved1987]

is it the same spot on 2 and a 4 door?