has anyone cut a access hole fuel pump?

[2003vstrom]

has anyone cut a access hole for the fuel pump on a 3rd gen? I was looking at where about where I would have to cut the hole and looks like it would be right behind the front passenger seat thats about where the pick-up area is mold in the tank and info would be great thanks

 

[thepotroast]

The fuel pump is submerged into the fuel tank...I'm not so sure cutting an access hole there would be a good idea

 

[fishwish3]

one word of advice DO NOT CUT INTO THE TANK! you may just cause more problems then you would really want to.

 

[2003vstrom]

yeah I know the fuel pump is submerged in the tank I have worked on them before there is a thread on the 2 gens where guys have cut access holes, it makes it alot easier too access the the fuel pump when you have trouble, I`m just wondering with mine having 157000 miles, hard to tell when it could go to hell, I was just wondering if anyone has done it on the 3 gens, there is at least a 1-2" of clearence between the the bottom of the body and the top of the tank, It looks pretty easy to do so I will just make a new access plate at work. I was wondering if anyone had done it before

 

[fishwish3]

i wouldnt just because it will never really be fully fuel tight again once you start cutting

 

[corkey]

i would drop the tank the first time to make sure you do cut the hole in the floor right the first time, also , the shower of sparks on the tank top, or the resulting drip of some kind of hot metal could be catastrophic, ,

 

[fishwish3]

i just wouldnt cut it at all, i would just drop the tank when it goes, MUCH safer.

 

[jhard]

Ok, I appreciate the "safety" angle... but that's being overly cautious. As stated by 2003vstrom it's been successfully done by quite a few 2nd Gen owners as seen in this thread: http://explorerforum.com/forums/showthread.php?t=182160

There's mention of using an "air chisel" by a few guys which doesn't produce ANY sparks what so ever.

I'm also trying to determine where to cut in the 3rd gen, as it would be much easier to perform a DIY fuel pump swap, as opposed to paying an overpriced mechanic multi-hours of labour to drop the tank, etc.

 

[eXcali]

Why would you pay a mechanic to drop your fuel tank? I've done many and it would take just about as much effort as cutting an access panel.

 

[2003vstrom]

Ok, I appreciate the "safety" angle... but that's being overly cautious. As stated by 2003vstrom it's been successfully done by quite a few 2nd Gen owners as seen in this thread: http://explorerforum.com/forums/showthread.php?t=182160

There's mention of using an "air chisel" by a few guys which doesn't produce ANY sparks what so ever.

I'm also trying to determine where to cut in the 3rd gen, as it would be much easier to perform a DIY fuel pump swap, as opposed to paying an overpriced mechanic multi-hours of labour to drop the tank, etc.

yeah I`m thinking about doing mine this weekend, I will take pictures and post them to show where I had to cut the hole, it looks me if you get down on the ground and look at the bottom of the tank where the anti-slosh is molded in the tank, looks like it lines up pretty well with the door gap between the front door and the rear door, if thats the case it might be right behind the front passenger seat, I still have to measure over from the side of the truck and see about where its going to be

 

[jhard]

Why would you pay a mechanic to drop your fuel tank? I've done many and it would take just about as much effort as cutting an access panel.

Because not all of us have a garage and supplies to maneuver with a FULL gas tank.

From what I've been told, it's safer to do it with a full tank as more gas vapor develops the more air there is in the tank.

Either way, we want to do it, and it's been proven feasible.

 

[2003vstrom]

Why would you pay a mechanic to drop your fuel tank? I've done many and it would take just about as much effort as cutting an access panel.

with all the tools I have and the ease of standing up and cutting the hole will be a piece of cake, and instead of crawling around underneath the truck , plus the ability to check the cleaniness of the fuel strainer, without having to drop the tank, it probably only take me 5 mins to cut the hole, I would never pay a anyone to work on my truck unless it was a major body damage, everything else I do myself, motor rebuilds and etc.

 

[jhard]

yeah I`m thinking about doing mine this weekend, I will take pictures and post them to show where I had to cut the hole, it looks me if you get down on the ground and look at the bottom of the tank where the anti-slosh is mold in the tank, looks like it lines up pretty well with the door gap between the front door and the rear door, if thats the case it might be right behind the front passenger seat, I still have to measure over from the side of the truck and see about where its going to be

Awesome man, looking forward to seeing the pics!

 

[thepotroast]

I guess to me it would make sense to do something like this for a part that sees regular maintenance and/or replacement....but what's the purpose of doing it for a fuel pump? You'll likely only replace the fuel pump once in the vehicle's lifetime....I know, I just had mine replaced from the dealer, at 132k miles....

Why go through the trouble of cutting holes for a fuel pump access....it's not something that most people ever have to replace

 

[2003vstrom]

well I plan on having this truck until the body falls off, or it gets totaled, so anything that makes my job easier, with my limited time. all ready have a aluminum access plate made to the general size I will need, will see how it goes, I have the air chisel in hand I just need to do some measuring to make sure I get the hole in the right place. :

 

[FasterFrank]

Hi 2003vStrom:
What did you find?
Any results, comments, pix you can contribute?
I am about ready to do my girlfriend's.
And if I screw it up I might be a dead duck.
Any knowledge will be greatly appreciated.
2002 Ford Explorer 4 door XLT
Thanks!
Faster Frank

 

[drdoom]

i just wouldnt cut it at all, i would just drop the tank when it goes, MUCH safer.

 

[FasterFrank]

Hi drdoom- if you go through this thread and more critically, the very lengthy one for accessing the fuel pump through a well-placed port in the first gen cars (http://www.explorerforum.com/forums/showthread.php?t=182160), you will see tons of forum members have stated undeniably and categorically that doing this operation is one of the best procedures they have ever undertaken in getting at their absurdly designed and positioned fuel pumps...
I am committed to doing it and am far beyond opinions to the contrary at this point.
But thanks for the note.

 

[Tankentaisha]

has anyone cut a access hole for the fuel pump on a 3rd gen? I was looking at where about where I would have to cut the hole and looks like it would be right behind the front passenger seat thats about where the pick-up area is mold in the tank and info would be great thanks

Sure annoying when you can start a thread with a simple question like this only to have people who need to learn something start in on why your plan is something you should give up on.

It's an absolutely great idea and one I plan on doing as well. None, not one of the naysayers has lain under a rig and pulled a full gas tank out on their chest and then had to have their girlfriend help maneuver the still full tank back in place after changing the pump.

The best approach is to do it on a fairly empty tank when you can easily move the tank around and away from the vehicle. Auto manufacturers also need to start putting these access plates in all vehicles and not just some as they do now. Very famous problem and not just with Ford, but so easy to get to the fuel pump once it has been made accessible.

Sure be great to see this thread updated with pictures!

 

[2003vstrom]

been a long time since I been on here, I have moved on long time ago from my 02 explorer, I can`t believe this thread is alive still , lol, I have since had a 07 sport trac and now i have 2011 f150 screw ecoboost 4x4, it not a hard job at all, unbolt front seat slide it forward, just do some measuring and just cut a little hole to see where ur at, then adjust according to where you see the center of the fuel pump hole is, I used 4" grinder with cut-off wheel and it sliced through the bottom like it was butter.