mlochala
Active Member
- Joined
- March 18, 2010
- Messages
- 56
- Reaction score
- 4
- City, State
- Amory, MS
- Year, Model & Trim Level
- 1998 Mountaineer AWD
When my wife and I purchased her '98 Mountaineer a long, long time ago, it didn't take long to learn that when it was low on gas (less than 1/4 tank), it didn't take much of an downhill incline to starve the engine of fuel. I just accepted it as a characteristic of the vehicle and decided to live with it cautiously.
However, recently I replaced the fuel pump and what used to just be a minor annoyance quickly became a real safety hazard. After replacing the fuel pump, the vehicle began starving for fuel as soon as the fuel gauge read 1/4 tank. When the fuel got to that level, the Mountaineer would begin stalling and even completely dying when stopping at an intersection or on a downhill incline. There was never a warning light indicating that the fuel level was too low.
One day, while stopping to check our mail, it died while sitting in our driveway with just over 1/4 tank of gas in it. The driveway has a very slight incline.
Where this problem started was when I replaced the original fuel pump back in September. I purchased an Airtex fuel pump and strainer from Autozone as a replacement for the OEM units. I also replaced the fuel filter.
I had zero problems installing the new pump, save for a few frustrations with the snap locks on the Ford fuel lines. I cut those out and replaced them with some good quality high pressure rubber lines. Everything should have worked perfectly but the problems began immediately after.
Since then, I've removed the tank several times to locate the problem. I looked for damaged or pinched fuel lines. I replaced and repositioned the strainer. I won't go into all the boring details, but after exhausting everything I could think of, it dawned on me that perhaps the pump wasn't low enough in the tank. When I originally installed the new unit, I was in a hurry and didn't take time to study the original pump and how it was mounted. I just assumed the new one would install just the same.
This past week, I once again (6th time) removed the tank and fuel pump assembly. After taking some careful measurements, I discovered the fuel pump intake was almost 3/4" from the bottom of the tank. Not only that, but there was no way to install the fuel pump without the strainer bunching up against the side of the inner tank reservoir. With the way the fuel pump bracket is made, there is no way to adjust the depth of the fuel pump nor adjust the direction of the strainer. I also noticed that the rubber boot that came with the new pump was enlarged and seemed to be interfering with how the strainer was connected to the fuel pump.
So, here is what I did. I removed the fuel pump from the assembly and then very carefully cut off the foot of the fuel pump bracket with a chop saw. Then, I also very carefully shaved off the tabs where the clamp mounts to secure the fuel pump. Once this was done and I had smoothed all the cut edges, I replaced the fuel pump and secured it loosely with a standard metal hose clamp. I replaced the short length of rubber fuel line on the assembly with one that was about 5/8" longer. I also slightly trimmed the rubber boot where the strainer attaches to the fuel pump so that it could not cause any interference.
I then measured and trial fitted the new pump depth until it could reach the bottom of the tank with the strainer laying flat on the bottom. Also, with the bracket foot removed, I could now turn the pump so that the strainer would not be crammed against the side wall of the reservoir. Now, it faces just slightly more toward the front of the vehicle.
As for the results of my efforts, I can now safely say I have finally resolved the issue. Immediately after replacing everything and putting just enough gas back into the tank to put it at about 1/4 tank, I took it for a drive. It immediately cranked up fine and has not stalled since. As a matter of fact, we put about 60 miles on it AFTER it dropped below the 1/4 tank line. I drove it until the fuel level indicator was below the "E" mark before putting any more gas into it. It never stalled nor stuttered one time, and has not since then.
I know this is a long post, but I wanted to share this in case anyone else out there is having similar issues. I know I have read here and there about others having issues with their Mountaineers/Explorers being sensitive to low fuel levels. Perhaps this might also be a solution that will also work for them.
Have a great day!
Mark
However, recently I replaced the fuel pump and what used to just be a minor annoyance quickly became a real safety hazard. After replacing the fuel pump, the vehicle began starving for fuel as soon as the fuel gauge read 1/4 tank. When the fuel got to that level, the Mountaineer would begin stalling and even completely dying when stopping at an intersection or on a downhill incline. There was never a warning light indicating that the fuel level was too low.
One day, while stopping to check our mail, it died while sitting in our driveway with just over 1/4 tank of gas in it. The driveway has a very slight incline.
Where this problem started was when I replaced the original fuel pump back in September. I purchased an Airtex fuel pump and strainer from Autozone as a replacement for the OEM units. I also replaced the fuel filter.
I had zero problems installing the new pump, save for a few frustrations with the snap locks on the Ford fuel lines. I cut those out and replaced them with some good quality high pressure rubber lines. Everything should have worked perfectly but the problems began immediately after.
Since then, I've removed the tank several times to locate the problem. I looked for damaged or pinched fuel lines. I replaced and repositioned the strainer. I won't go into all the boring details, but after exhausting everything I could think of, it dawned on me that perhaps the pump wasn't low enough in the tank. When I originally installed the new unit, I was in a hurry and didn't take time to study the original pump and how it was mounted. I just assumed the new one would install just the same.
This past week, I once again (6th time) removed the tank and fuel pump assembly. After taking some careful measurements, I discovered the fuel pump intake was almost 3/4" from the bottom of the tank. Not only that, but there was no way to install the fuel pump without the strainer bunching up against the side of the inner tank reservoir. With the way the fuel pump bracket is made, there is no way to adjust the depth of the fuel pump nor adjust the direction of the strainer. I also noticed that the rubber boot that came with the new pump was enlarged and seemed to be interfering with how the strainer was connected to the fuel pump.
So, here is what I did. I removed the fuel pump from the assembly and then very carefully cut off the foot of the fuel pump bracket with a chop saw. Then, I also very carefully shaved off the tabs where the clamp mounts to secure the fuel pump. Once this was done and I had smoothed all the cut edges, I replaced the fuel pump and secured it loosely with a standard metal hose clamp. I replaced the short length of rubber fuel line on the assembly with one that was about 5/8" longer. I also slightly trimmed the rubber boot where the strainer attaches to the fuel pump so that it could not cause any interference.
I then measured and trial fitted the new pump depth until it could reach the bottom of the tank with the strainer laying flat on the bottom. Also, with the bracket foot removed, I could now turn the pump so that the strainer would not be crammed against the side wall of the reservoir. Now, it faces just slightly more toward the front of the vehicle.
As for the results of my efforts, I can now safely say I have finally resolved the issue. Immediately after replacing everything and putting just enough gas back into the tank to put it at about 1/4 tank, I took it for a drive. It immediately cranked up fine and has not stalled since. As a matter of fact, we put about 60 miles on it AFTER it dropped below the 1/4 tank line. I drove it until the fuel level indicator was below the "E" mark before putting any more gas into it. It never stalled nor stuttered one time, and has not since then.
I know this is a long post, but I wanted to share this in case anyone else out there is having similar issues. I know I have read here and there about others having issues with their Mountaineers/Explorers being sensitive to low fuel levels. Perhaps this might also be a solution that will also work for them.
Have a great day!
Mark
