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Fuel Pump Electrical Connection to Assembly or Sending Unit

Awesome96XLT

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Year, Model & Trim Level
96 xlt
Hey guys. As some of you may know, I just switched out my fuel pump on my 96 4.0 l. It was succesful and the explorer is now up and running with even better mileage :thumbsup:.

I have a question about the electrical connection between the pump to the assembly.

I bought a pump and connected it to the assembly via crimp connectors.
I did not have the crimp tool so I used a pair of normal adjustable flat nose pliers, using where it intersects (on the inside, not the nose part) to crimp the connectors. I crimped very hard multiple times and it seemed fine.

I was wondering if this is sufficient strength to hold the wires together in the tank and the possibility of cracking or opening up the crimp connector my crimping card multiple times with normal flat head pliers where it intersects. I know I should have used the right tool but I needed my truck asap. Now I am contemplating dropping the tank again or using a hammer and a chisel to cut the floor to access the sending unit and crimp the connection correctly.

Do you guys think it is worth doing or is it fine.

What are the chances of electricity arcing and causing an explosion in the gas tank?

thanks to anyone who answers! :exp:
 






Are the wires tight after you crimped them?

Hey guys. As some of you may know, I just switched out my fuel pump on my 96 4.0 l. It was succesful and the explorer is now up and running with even better mileage :thumbsup:.

I have a question about the electrical connection between the pump to the assembly.

I bought a pump and connected it to the assembly via crimp connectors.
I did not have the crimp tool so I used a pair of normal adjustable flat nose pliers, using where it intersects (on the inside, not the nose part) to crimp the connectors. I crimped very hard multiple times and it seemed fine.

I was wondering if this is sufficient strength to hold the wires together in the tank and the possibility of cracking or opening up the crimp connector my crimping card multiple times with normal flat head pliers where it intersects. I know I should have used the right tool but I needed my truck asap. Now I am contemplating dropping the tank again or using a hammer and a chisel to cut the floor to access the sending unit and crimp the connection correctly.

Do you guys think it is worth doing or is it fine.

What are the chances of electricity arcing and causing an explosion in the gas tank?

thanks to anyone who answers! :exp:

Even if you didn't use a pair of "crimping pliers" as long as the wires are not loose inside the connector ends and insulated from making contact with bare metal there is little chance of arcing in any connection...

Now for your peace of mind if you believe the crimps could be better then by all means drop the tank and redo the connections...

I have personally used linemans' pliers to make connections and they have been fine...Good, solid contact, tight insulated connections that have lasted for years...But I can't determine how good your connections were since I didn't make them...

That, my friend, is why i work on my own stuff. I KNOW what was done and how it was done...If I need to redo something, it is usually because I don't feel good about what I did in the first place...But when something breaks, I also have a pretty good idea of what and why...

Since the truck is back in service and running well obviously the connections are working and not shorting out or dropping power...But whether you recheck the pump wires is gonna have to be your call...
 






If you decide to cut an access panel in the floor you can cut it with a decent pair of tin shears.I did mine with tin shears a couple of years ago when I replaced my fuel pump.Do a search for fuel pump access panel and you will find lots of info on access panels.You might not ever have a problem with the connections But I'm a worry wort and I'd be worried they'd vibrate loose and I'd be stranded some place with no working fuel pump.I feel the percentages are in your favor if you leave it as is.It's all in how you feel about it.Good luck.in whatever you decide.
 






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