Fuel pump swap

Tiny
WILLIAM EDELEN
  • MEMBER
  • 1996 FORD EXPLORER
  • 4.0L
  • V6
  • 2WD
  • AUTOMATIC
  • 5,000 MILES
It will start up sometimes. I think it is the fuel pump. If I take a fuel pump out of a 2000 Ford Mustang v6 Will it work?
Saturday, April 6th, 2019 AT 8:51 PM

2 Replies

Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,747 POSTS
Welcome to 2CarPros.

No, the pump won't cross to this vehicle. You need one specific for this car. Before you replace the pump, I suggest checking fuel pressure to confirm the pump is bad. Here is a link that shows how in general one is tested:

https://www.2carpros.com/articles/how-to-check-fuel-system-pressure-and-regulator

Picture 1 below indicates the manufacturer's pressure specs.

____________________________________

Here are the directions for replacing the pump if you find it to be bad.

Tank removal (see picture 2)

Removal and Installation

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

1. Drain fuel from fuel tank. This can be done by disconnecting the fuel tank filler pipe from the tank filler neck.

2. Support fuel tank, then remove the 10mm fasteners at the front fuel tank support.

3. Loosen the fuel tank support strap (making sure tank is supported) and remove.

4. Lower the fuel tank then disconnect the fuel lines from sender tubes and electrical connector. Remove the vapor valve hose. Remove the remaining fuel filler vent pipe.

5. For installation, follow removal procedure in reverse order.

Tighten front support bolts to 34-46 Nm (25-34 lb.ft.).

Install fuel tank support strap and tighten bolt to 34-46 Nm (25-34 lb.ft.).

NOTE: Refer to illustration for proper installation of fuel tank filler pipe making sure horseshoe clip is engaged.

_________________________

Pump removal and replacement Pics 3 and 4 correlate with these directions.

CAUTION: Fuel supply lines remain pressurized for long periods of time after the engine is shut down. This pressure must be relieved before the fuel system is serviced: See: Fuel Pressure Release > Service and Repair

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

Removal

1.Remove fuel tank: See: Fuel Tank > Procedures

2.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.

3. Unscrew the (6) M6 fasteners and remove the Fuel Delivery Module (FDM) from the fuel tank.

Installation

1.If necessary, install fuel tank sending unit and two screws. Connect spade connector.

2.Clean the fuel pump mounting flange and the fuel tank mounting surface and groove in fuel tank sending unit locking retainer ring.

3.Put a light coating of Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B on a new fuel pump mounting gasket to hold it in place during assembly and install it in the fuel ring groove.

4.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.

5.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 T90T-9275-A.

6.Install the replacement unit and hand start the (6) M6 fasteners. Torque fasteners to 9-12 Nm (7-9 lb.ft.).

Let me know if this helps or if you have other questions.

Take care,
Joe
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Saturday, April 6th, 2019 AT 10:22 PM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,747 POSTS
Welcome to 2CarPros.

No, the pump won't cross to this vehicle. You need one specific for this car. Before you replace the pump, I suggest checking fuel pressure to confirm the pump is bad. Here is a link that shows how in general one is tested:

https://www.2carpros.com/articles/how-to-check-fuel-system-pressure-and-regulator

Picture 1 below indicates the manufacturer's pressure specs.

____________________________________

Here are the directions for replacing the pump if you find it to be bad:

Tank removal (see picture 2)

Removal and Installation

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

1. Drain fuel from fuel tank. This can be done by disconnecting the fuel tank filler pipe from the tank filler neck.

2. Support fuel tank, then remove the 10mm fasteners at the front fuel tank support.

3. Loosen the fuel tank support strap (making sure tank is supported) and remove.

4. Lower the fuel tank then disconnect the fuel lines from sender tubes and electrical connector. Remove the vapor valve hose. Remove the remaining fuel filler vent pipe.

5. For installation, follow removal procedure in reverse order.

Tighten front support bolts to 34-46 Nm (25-34 lb.ft.).

Install fuel tank support strap and tighten bolt to 34-46 Nm (25-34 lb.ft.).

NOTE: Refer to illustration for proper installation of fuel tank filler pipe making sure horseshoe clip is engaged.

_________________________

Pump removal and replacement Pics 3 and 4 correlate with these directions.

CAUTION: Fuel supply lines remain pressurized for long periods of time after the engine is shut down. This pressure must be relieved before the fuel system is serviced: See: Fuel Pressure Release > Service and Repair

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

Removal

1.Remove fuel tank: See: Fuel Tank > Procedures

2.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.

3. Unscrew the (6) M6 fasteners and remove the Fuel Delivery Module (FDM) from the fuel tank.

Installation

1.If necessary, install fuel tank sending unit and two screws. Connect spade connector.

2.Clean the fuel pump mounting flange and the fuel tank mounting surface and groove in fuel tank sending unit locking retainer ring.

3.Put a light coating of Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B on a new fuel pump mounting gasket to hold it in place during assembly and install it in the fuel ring groove.

4.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.

5.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 T90T-9275-A.

6.Install the replacement unit and hand start the (6) M6 fasteners. Torque fasteners to 9-12 Nm (7-9 lb.ft.).

Let me know if this helps or if you have other questions.

Take care,
Joe
Was this
answer
helpful?
Yes
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Saturday, April 6th, 2019 AT 10:22 PM

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