Removal and Replacement

FUEL TANK

Explorer Sport Trac (Part 1):

Explorer Sport Trac (Part 2):

Explorer/Mountaineer (Part 1):

Explorer/Mountaineer (Part 2):

Exploded View

Removal and Installation

All vehicles

WARNING:
- Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
- Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.
- When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.

NOTE: During the repair or replacement of fuel-related components, all liquid and vapor fuel openings must be capped, taped or otherwise appropriately protected to prevent the ingress of dirt or other contamination. All caps, tape and other protective materials must be removed prior to installation.

1. With the vehicle in NEUTRAL, position it on a hoist.
2. Release the fuel system pressure.
3. Disconnect the battery negative cable.

Explorer/Mountaineer
4. Remove the driveshaft.

All vehicles
5. Drain the fuel tank.







6. If equipped, remove the 4 bolts and the transfer case skid plate.
- To install, tighten to 40 Nm (30 lb-ft).

7. Disconnect the filler pipe vapor tube-to-fuel pressure sensor and vapor tube assembly quick connect coupling.
8. Disconnect the fuel vapor hose from the evaporative emissions (EVAP) canister vent valve.

Explorer/Mountaineer







9. Remove the bolts and the fuel filter heat shield.
- To install, tighten to 20 Nm (15 lb-ft).

All vehicles







10. Remove the nuts and the fuel filter shield.
- To install, tighten to 6 Nm (53 lb-in).

11. Disconnect the fuel filter outlet quick connect coupling.
12. Disconnect the fuel pressure sensor and tube assembly-to-vapor tube quick connect coupling.
13. If equipped, remove the 4 bolts, 1 nut and the fuel tank skid plate.
- To install, tighten to 40 Nm (30 lb-ft).







14. Using a suitable jack, support the fuel tank.
15. Remove the bolt and the fuel tank rear support strap.
- To install, tighten to 48 Nm (35 lb-ft).

16. Remove the nut and the fuel tank front support strap.
- To install, tighten to 48 Nm (35 lb-ft).

17. Lower the fuel tank far enough to access the fuel pump electrical connector and disconnect the connector.
18. Remove the fuel tank from the vehicle.

19. NOTE: Make sure the fuel and vapor tubes are correctly routed prior to installing the fuel tank.

To install, reverse the removal procedure.