Removal -Fuel Sender Feed and Return Lines

[explorerscope]

Can someone urgently help me with this. I search post and haven't found anything. I just getting back up my fuel tank, but I have to change the lock ring which I just got this evening,which lock the pump/sender assembly in place. I need to disconnect the 3/8 and 5/16 feed and return lines from the sender to get the lock ring on but the dang couplings won't come loose. I brought the plastic tool and the metal tool to disconnect these line but none work. I looked carefully at the lines and it seems to me like a simple lock mechanism, I tried to place the tool in position, push the line towards the tool and snap it off but nothing..I'm thinking maybe its dirt blocking the metal joint things from unlocking...I'm really in need to get my truck back on the road and reached so far, and I'm stuck....what am I doing wrong? Please help!!!

 

[Eneurb]

Spray penatrating oil into the lines and give them a twist back and forth, blow them out with compressed air if available. They can be very difficult to remove at times, but patience normally pays off. If you end up damaging them getting them, your local dealer should have new inserts for the lines.

 

[explorerscope]

Oh, well it seems simple enough, but gess, I been trying all evening. I got the metal sisors tool(3/8 with 5/8 from NAPA, Is this the right tool for the job? there are so many different ones online.So much for calling them quick disconnect! my foot!!! I got a can of compressed air somewhere around.

 

[explorerscope]

Update: still no luck...I saw a post that said the sissors disconnect tool dosent work, well guess what, it dosent...plus mine has just broken using hand strength. Stay away from the NAPA version of this tool. Has anyone brought a quick disconnect tool that work with 1993 explorer model, if so where is a good place to get one?

 

[Robman7835]

I too had a hell of a time when i did the fuel pump/sending unit on my 93. i had the same little plastic tools that i got from autozone and they didnt seem to work at first but like someone else said just spray some rust catalyst on them and just keep playin with em'. i had a worse time getting them back on then off. Good luck

 

[explorerscope]

Can that lil joint where the stainless steel meets the flexible line, be removed? Man, I just feel like putting a hack saw to those dang lines. Is a rust catalyst like WD40? or something stronger? I want something to fry that junk in there all up

 

[Dre]

WD40 might not work... try either PB Blaster or something of sorts...

 

[oSPANNERo]

Removal

NOTE: On some vehicles, fuel gauge sending unit is not available separately. On those vehicles, to replace sending unit, replace entire fuel pump .

Remove fuel tank as described in this section.
Remove fuel tank to bench. Remove any dirt that has accumulated around the fuel pump attaching flange so that it will not enter the fuel tank during fuel pump removal.
Turn the fuel tank sending unit locking retainer ring (9A307) counterclockwise with the Fuel Tank Lock Ring Wrench Tool T90T-9275-A or T86T-9275-A and remove fuel tank sending unit locking retainer ring .
Remove the fuel pump and sender assembly.
Remove fuel pump mounting gasket (9417) and discard.
If necessary, disconnect spade connector and remove two screws and fuel gauge sending unit.

Installation

If necessary, install fuel tank sending unit and two screws. Connect spade connector.
Clean the fuel pump mounting flange and the fuel tank mounting surface and groove in fuel tank sending unit locking retainer ring .
Put a light coating of Premium Long-Life Grease XG-1-C or -K (ESA-M1C75-B) or equivalent grease on a new fuel pump mounting gasket to hold it in place during assembly and install it in the fuel ring groove.
Install fuel pump and sending unit assembly carefully to make sure that the filter is not damaged. Be sure that the locating keys are in keyways and the fuel pump mounting gasket remains in place.
Hold the fuel sending unit and fuel pump mounting gasket in place. Install and rotate the fuel tank sending unit locking retainer ring clockwise using Fuel Tank Lock Ring Wrench Tool T90T-9275-A.
For Ranger and Aerostar, tighten the fuel tank sending unit locking retainer ring to 55-74 Nm (40-55 ft-lb).
For Ranger SuperCab and Explorer, tighten fuel tank sending unit locking retainer ring clockwise until stop.
Install fuel tank as described in this section.

 

[oSPANNERo]

Steel Midship, Explorer



Removal and Installation

NOTE: Make sure fuel tank is properly supported during removal and installation procedures.

Drain fuel from fuel tank .
Remove fuel tank heat shield and fuel tank front fuel tank support strap .
Support fuel tank and remove bolt from rear fuel tank support strap .
Loosen screw clamps from fuel tank filler pipe and vent pipe and remove from fuel tank .
Lower fuel tank .
Remove fuel vapor return tube from vapor valves.
Disconnect fuel sender and fuel pump connector from rear of fuel tank .
For installation, follow removal procedures in reverse order. Tighten bolts securing front and rear Fuel tank support straps to 37-50 Nm (28-36 ft-lb). Tighten bolts securing fuel tank heat shield to 37-50 Nm (28-36 ft-lb). Tighten clamp securing fuel tank filler pipe to 3-4 Nm (27-35 in-lb).

 

[DeRocha]

Check out this Fuel filter removal thread. It has lots of detailed info and pictures to explain how the clips are holding the fittings in place.

 

[bigmitch101]

I just got done (yesterday) replacing the fuel pump on my truck, and I had a heck of a time with these lines. Make sure you're pushing the plastic tool all the way in. I used a pair of Channel locks to push the tool in all the way. My lines were really corroded. Don't be afraid to pull on the line.

 

[Dre]

if the truck is a bit older I would replace the lines as well if they were corroded even a bit.

just me,