Fuel filter lines for a 2002 and other problems.

[rjhart]

I decided to jump into replacing the fuel pump on my friend's dad's 2002 Explorer b/c he is tight on cash. It's turned into a bear of a job. My first problem is getting the two fuel lines going into fuel filter off. They do not use the quick disconnect tool that the out-going fuel line uses, and having never seen similar lines, I am not sure exactly how to get them off. Here is a picture of them:

My second problem is going to be a bit more problematic. The welded stud holding one of the fuel tank straps has broken loose -- it spins with the bolt. I do not know the best way to get the bolt and strap off. The best thing I can think of is to have a vice grip on the end of the stud and use a ratchet on the bolt (that has worked once for me). I am hesitant to use power tools because of the potential fire hazard, being near the gas tank and all. Any ideas? I really don't have too much time to mess around with it.

 

[Drewmcg]

I have a solution to both problems: don't remove the fuel tank. Instead, search the forum for instructions how cut the floor of the right rear passenger area--just behind the front passenger seat--to access the fuel pump that way. This is what I did and it worked great. You need to unbolt the front passenger seat (easy), unclip the sensor wires underneath the seat (easy); unbolt the right rear seat and bungie up and away the carpet. Cut three sides of a rectangle directly over the fuel pump and peel back the flap. Get a Delhi pump (other not as reliable; too expensive)--check Amazon.

I went to Menards and bought a stainless steel square piece of metal (roughly 12"x12" or so) and patched the hole with some sheet metal screws (not easy). Better still was some 10" or so wide strips of "self-sealing membrane" used for roofing applications that I bought from Lowes (not cheap). A few layers of that overlapped, slap the carpet back down, bolt the seats up, and off you go!

Not a bad idea to replace the fuel filter afterwards. There are youtube videos (check Ford TechMakuloco (sp?)) on how to get those red clips off, or search on this site. Good luck.