Fuel Pump Replacement on a 2003 Sport Trac By: David Rheman This is how I changed the fuel pump on my 2003 Ford Explorer Sport Trac 4x2. This is for possible information ONLY! Anything I say or do here that causes you to say or do anything is completely at your own risk! Dont do something stupid just because I did it and may have gotten away with it so far! Tools: 13mm Socket for the tank strap bolts (but a worked as well) Ratchet Extensions (for the back bolt) Floor Jack Jack Stands Ramps Fuel line fitting release tool LARGE flat bladed screwdriver Mallet (I used a brass mallet, but almost any hammer will work) Parts: New Fuel Pump (Mine came from Ford, part #3L2U-9H307-EB) Re-use old fuel pump gasket and big plastic nut

Step 1.

Put the back of the truck up on ramps. Hopefully yours will do like mine did and will run for long enough to get it up there!

Step 2.

Put chocks under one of the front tires. Theres almost nothing worse than being under a car that starts rolling!

Step 3.

This is a picture of the bolt you will have to take out to release the front strap that holds the tank in. The other end of the strap fits into a slot in the frame, so one bolt is all you need to release the strap.

Step 4.

This is a picture of the bolt for the back strap. You will need a long extension or really skinny arms to reach past the driveshaft!

Step 5.

I used a rope from one side tie-down to the front of the bed and down past the driveshaft to the tank and back up again on the other side. The fishing pole helps fish the line back up the other side.

Step 6.

This really isnt a step, but here you can see where the rope goes underneath. The strap is already off in this picture. Please put the rope in place BEFORE you release the strap!

Step 7.

I used a jack stand to hold up the front. With a half a tank of gas it wasnt too bad, but I should have used a small board between the jack stand and the tank to distribute the weight better!

Step 8.

Partway down the tank suddenly wont go any farther. Youll have to reach up and unscrew the clamp to the filler neck hose attachment to the tank.

Step 9.

I took this picture to show the clips holding the fuel line to the tank. I released the clips to allow the fuel line to move away from the tank. I later realized its easier to release the lines from the fuel filter and take them out with the tank.

Step 10.

Here are the tank straps on the ground. You see the bolt on one end and the T on the other end that slips into a slot in the frame.

Step 11.

Heres the tank halfway down. Take it slow and easy, a little down on one end then a little down on the other end. Keep an eye on the vent hoses so you can pull them loose when you can get to them. Now is a good time to find the wire to the pump and release it from its socket, which is against the frame crossmember.

Step 12.

Here is the tank on the ground!

Step 13.

Here is the tank out of the truck! Now you can release the fuel lines from the fuel pump. These used the same fittings that attach to the fuel filter, so the same tool should work.

Step 14.

This is the top of the fuel pump. You will need to unscrew the big grey ribbed ring to get the pump out. I found that a large flatbladed screwdriver against the ribs of the nut worked ok to get the nut to turn. I used a brass mallet to smack the end of the screwdriver. It took some work to get it going, but it finally started moving.

Step 15.

This is why I had trouble finding the right pump. My old pump had five pins in the electrical socket, and all the aftermarket pumps had four pins! And all said Its yours if you hook it up! No returns on installed electrical items! Autozone had a five pin pump shown, but they had to order it from out of state! I finally got the number off the old pump and had a friend at a Ford dealership chase it down. It turns out the four pin pump supercedes the five pin pump! He got me a good price, too! I didnt even know he worked there! Ask your friends if they work at Ford!

Step 16.

Here is the new, four pin connector.

Step 17.

Here is the old pump.

Step 18.

Here is the new pump. Looks a lot better, doesnt it?

Step 19.

Here is a picture of the fittings on the fuel filter end. They look the same as the fittings on the pump end. I didnt think so at first, so I tried other ways to remove the fittings, and wound up messing up one of the fittings. Use the same method to remove the fittings from the pump that you use to remove the fittings from the filter!

Step 20.

Here is the new pump installed in the tank. The big plastic nut takes a little patience and work to get it lined up and threaded right. Find the start of the threads on the nut and the start of the threads on the tank and set them into each other, then push the other side of the nut down until its level. Then start threading the nut onto the tank. It should go by hand until snug, then use the mallet and screwdriver again to seat it tightly.

Step 21.

Those of you with sharp eyes may have noticed that the last picture showed a slightly modified clip for the fuel line! I wound up busting the larger one before I realized it was the same as the fuel filter clip. I tried all the parts stores I could think of on a late Saturday, but none of them carried that clip! So I shoved the line onto the pump, stuffed the remaining part of the clip into the slot and around to the back, and it seemed to hold. I knew it wouldnt stay there, so I threaded a zip-tie around the clip and through the holes in the fitting. It keeps the clip from rotating, and it ought to stay, but well see!

Step 22.

Here is the finished tank, ready to go back in the truck! Take your time getting it back up in there, but it really isnt all that hard. The rope trick used to let it down doesnt work very well to lift it back up, but it does help to keep the tank from falling if it slips off the jack. Use a board on a floor jack to lift it a little at each end. Use the rope to hold it at the back and the jack stand to hold it at the front, and back and forth until its in! Dont forget to hook up the vent hoses, filler hose, and electrical connector before the tank is all the way up! Use dielectric grease inside the connector to keep moisture out of the connection.
Step 23. (No Picture) When you fire it up, remember that the lines are empty and need to refill and re-pressurize before it will start, so give it a minute with the key in the on position before you try to start it. If it doesnt start on the first try, give it a minute more. Mine took three tries before it would start! Afterword: Theres more to the story. Two days after changing the pump, my Trac died on the way to work. On a whim, I reached under the dash and pushed the button for the fuel cutoff switch, which is the switch that cuts power to the pump in an accident. It fired right up! I headed home, and she died twice more before I got there, but pressing the switch fixed it each time. When I got home, though, I found that the switch had melted the connector! So the switch was the problem all along, not the pump. But you got a project out of it, didnt you?

Rev. - Aug, 2004

2004 Ford Explorer Sport Trac
ACCESSORY DESCRIPTION For Use With Folding Hard Tonneau Cover With Ford Logo, Black Black With Ford Logo, Under-the-Rail Smoke-Color (Single-Pack) Smoke-Color (Bulk Pack of 10) Smoke-Color (Bulk Pack of 25) Smoke-Color (Bulk Pack of 50) Smoke-Color (Single-Pack) Smoke-Color (Bulk Pack of 10) Smoke-Color (Bulk Pack of 25) Smoke-Color (Bulk Pack of 50) PART NUMBER 1L2Z-99286A72-AA YL5Z-99112A15-AA 4L2Z-9900038-AAA 1L2Z-9900038-AA 1L2Z-16C900-FA 1L2Z-16C900-GA 1L2Z-16C900-HA 1L2Z-16C900-JA 1L2Z-16C900-BA 1L2Z-16C900-CA 1L2Z-16C900-DA 1L2Z-16C900-EA EST INSTALL DEALER SUGG FIT NET LIST TIME YEARS (Hours) PRICE* PRICE* 2001-2004 0.30 $68.53 $97.90 2001-2001-2004 2001-2004 2001-2004 2001-2004 2001-2004 2001-2004 2001-2004 2001-2004 2001-2004 2001-2004 D.I.Y. 0.50 0.50 0.30 0.30 0.30 0.30 0.30 0.30 0.30 0.30 D.I.Y. $32.93 $292.90 $227.25 $44.43 $392.89 $933.24 $1,760.43 $54.53 $492.48 $1,177.66 $2,221.50 $313.79 $47.04 $418.43 $324.64 $63.47 $561.27 $1,333.20 $2,514.90 $77.90 $703.54 $1,682.37 $3,173.57 $448.27

Bed Divider

Bed Mats Bed Rug, SportLiner Bedliners** Bug Shield Low Profile

Wraparound

Cargo Box Medium
Capacity of 15.5 cubic feet, Designed 1L2Z-7855100-CA to carry wider and slightly taller gear. Snowboards, two or three golf bags, camping gear or luggage. Capacity of 11.3 cubic feet, Designed 1L2Z-7855100-EA to carry (6) pairs of skis/poles, snowboards, waterskis, water sport, fishing, camping and cycling gear Stainless Steel Full, Black Sport Hood, Black Smoke-Color Primed Black Smoke-Color 4-Piece Set, Smoke-Color (Single-Pack) 1L2Z-99286A40-AA 1L2Z-19A414-AA 1L2Z-19A414-BA 1L2Z-19A412-JA 2L2Z-78500A26-AA 1L2Z-7844210-AAA 1L2Z-7844210-AAB 1L2Z-18246-BA F77Z-18246-BA

2001-2004

D.I.Y.

$270.80

$386.86
Cargo Cage/Bed Extender Cover, Front End Cover, Full Vehicle Deflector, Moonroof Deflectors, Rear Roof Air Deflectors, Rear Window Deflectors, Side Window
2001-2004 2001-2004 2001-2004 2002-2002-2004 2002-2004 2001-2004 2001-2004 2001-2004 2001-2004
0.50 0.30 0.30 D.I.Y. D.I.Y. 2.00 1.00 0.30 0.30 0.30 0.30
$281.16 $85.03 $48.76 $199.36 $38.89 $118.17 $180.25 $40.39 $54.53 $490.77
$401.66 $121.47 $69.66 $284.80 $55.56 $168.81 $257.50 $57.70 $77.90 $701.10
4-Piece Set, Smoke-Color (Bulk Pack YL2Z-18246-AA of 10) 4-Piece Set, Smoke-Color (Bulk Pack YL2Z-18246-BA of 25)

$1,090.60 $1,558.00

Estimated time for one technician with some install experience. D.I.Y. = Do-It-Yourself Item. * Prices subject to change without notice ** Quantity discounts may apply. See special order forms for details.
2004 Ford Explorer Sport Trac -- Page 1
ACCESSORY Deflectors, Side Window (continued) Door Edge Guards Engine Block Heater First Aid Kit With Ford Logo DESCRIPTION PART NUMBER FIT YEARS 2001-2004 2001-2004 2001-2004 2001-2004 2001-2004 2001-2004 EST INSTALL DEALER NET TIME (Hours) PRICE* 0.30 0.30 0.30 0.80 D.I.Y. D.I.Y. SUGG LIST PRICE*
4-Piece Set, Smoke-Color (Bulk Pack YL2Z-18246-CA of 50) 4-Piece Set, Stainless Steel 4-Piece Set, Matte Black 4.0L Engine
$2,167.02 $3,095.74 $33.33 $33.33 $23.82 $14.29 $262.88 $47.61 $47.61 $34.03 $20.41 $375.54
1L2Z-7820910-AA 1L2Z-7820910-BA F67Z-6D008-CA 1W7Z-19F515-AB
Includes an assortment of adhesive bandages, antibacterial ointment, sterile dressing, etc.
Includes an assortment of adhesive 2W7Z-19F515-AB bandages, antibacterial ointment, sterile dressing, etc. (Bulk Pack of 20) Floor Mats, All Weather Molded Vinyl Front Pair, With Logo Rear Pair Floor Mats, Carpeted Front Pair, With Logo & Full Rear, 3-Piece Set Hands-free Cell Phone Prep Harness Connector Wiring Harness Highway Safety Kit With Ford Logo Dk. Flint Dk. Pebble Dk. Flint Dk. Pebble Dk. Flint Dk. Pebble For Use With Molex Connectors For Use With Tyco Connectors Includes reflective triangles, fire extinguisher, thermal blanket, hose tape, basic tools, 12-hour light stick, and more Includes reflective triangles, fire extinguisher, thermal blanket, hose tape, basic tools, 12-hour light stick, and more (Bulk Pack of 6) Keyless Entry Keypad Driver's Side Keyless Entry Keypad (Single Pack) 3L2Z-1613086-DA 3L2Z-1613086-EA 3L2Z-1613106-FA 3L2Z-1613106-GA 1L2Z-7813300-AAE 1L2Z-7813300-AAF 4L2Z-19A393-AA 4L2Z-19A393-BA 1W7Z-19F515-AA
2003-2004 2003-2004 2003-2004 2003-2004 2003-2004 2003-2004 2001-2004
D.I.Y. D.I.Y. D.I.Y. D.I.Y. D.I.Y. D.I.Y. D.I.Y. D.I.Y. D.I.Y.
$33.94 $33.94 $20.89 $20.89 $48.08 $48.08 $33.38 $33.38 $61.89
$48.49 $48.49 $29.84 $29.84 $68.69 $68.69 $47.69 $47.69 $88.41

2W7Z-19F515-AC

$371.40

$530.57

3L2Z-14A626-AA

$99.99

$142.84
2004 Ford Explorer Sport Trac -- Page 2
ACCESSORY Keyless Entry Keypad (continued) DESCRIPTION Driver's Side Keyless Entry Keypad (Bulk Pack of 12) Driver's Side Keyless Entry Keypad (Bulk Pack of 96) PART NUMBER 3L2Z-14A626-BA 3L2Z-14A626-CA FIT YEARS 2001-2004 2001-2004 2001-2004 2001-2004 2001-2004 2001-2004 2001-2004 EST INSTALL DEALER NET TIME (Hours) PRICE* 0.80 0.80 1.00 1.00 1.00 0.50 0.30 SUGG LIST PRICE*
$1,151.40 $1,644.86 $8,726.40 $12,466.28 $54.42 $45.35 $139.67 $27.27 $28.91 $77.74 $64.79 $199.53 $38.96 $41.30
Lights, Automatic, Headlamp System Includes Daytime Running Lights Lights, Daytime Running Lights, Fog Lock Kit, Air Bag Anti-Theft Lock Kit, Wheel Anti-Theft Mirror, Electrochromic/Compass Homelink
For Vehicles With or Without Daytime F8AZ-13B218-AA Running Lights Original Equipment Lights Driver & Passenger Side Open-Ended, Zinc-Plated for Hidden Lugs, Includes (4) Lock Lugs and (1) Key F6SZ-13B218-AA 1L2Z-15200-AA F87Z-14B384-AA F5TZ-1A043-A
Without Temp. Display (Not Equipped 4L3Z-17700-AA With Auto Dimming Headlight Sensor) With Temp. Display (Not Equipped 4L3Z-17700-BA With Auto Dimming Headlight Sensor)

2003-2004

1.00 1.00 1.00

$280.00 $303.50

$373.33 $404.67

Navigation System

Navigation System - Bezel Kit Spring Clip Radio
Includes Radio Head, Code Card, Radio Removal Tool, Antenna & CD-Software, Steering Wheel Audio Controls Will Not Function With System Installed

2L2Z-18814-NAV

$1,036.26 $1,480.37
Includes Bezels, Brackets and Wiring 2L2Z-10E991-BA Harnesses, Install Time Included In Base Navigation System

$73.53

$105.04
2004 Ford Explorer Sport Trac -- Page 3
ACCESSORY Racks Bike Carrier, Bed Mount by Yakima Bike Carrier, Fork Mount by Yakima DESCRIPTION For Truck Bed, Carries (2) Bikes For Use With Raised Cross Bars, Carries (1) Bike For Use With Raised Cross Bars, Carries (1) Bike PART NUMBER 1L2Z-7855100-AA F75Z-7855100-EA F75Z-7855100-AA F75Z-7855100-BA FIT YEARS 2001-2004 2001-2004 2001-2004 2003-2004 2001-2004 2001-2004 2001-2004 2001-2004 2001-2004 2001-2004 2001-2004 2001-2004 2001-2004 2001-2004 2002-2004 2002-2004 EST INSTALL DEALER NET TIME (Hours) PRICE* D.I.Y. D.I.Y. D.I.Y. D.I.Y. D.I.Y. D.I.Y. D.I.Y. D.I.Y. 0.50 0.30 D.I.Y. D.I.Y. D.I.Y. D.I.Y. D.I.Y. D.I.Y. $102.04 $81.63 $102.04 $102.04 $21.26 $30.61 $80.53 $52.38 $161.60 $73.12 $23.82 $130.35 $88.00 $95.65 $88.00 $95.65 SUGG LIST PRICE* $145.77 $116.61 $145.77 $145.77 $30.37 $43.73 $115.04 $74.83 $230.86 $104.46 $34.03 $186.21 $125.71 $136.64 $125.71 $136.64

Bike Carrier, Frame Mount by Yakima For Factory Roof Rack, Carries (1) Bike Bike Carrier, Front Wheel Holder by Yakima Canoe Carrier by Yakima Cross Bars - O.E. Kayak Carrier by Yakima LoadWarrior by Yakima LoadWarrior Extension by Yakima LoadWarrior Off Road Light Bracket by Yakima
For Use With Fork Mount Bike Carrier F75Z-7850148-CA and Raised Cross Bars, Carries (1) Front Wheel For Use With Raised Cross Bars, Carries (1) Canoe For Use With Raised Cross Bars, Carries (2) Kayaks Original Equipment, Eliptical, Set of (2) 1L2Z-9855100-AA

F7DZ-5455100-AC

F7DZ-5455100-AB
For Use With Factory Rack or Raised 1L8Z-7855100-AA Cross Bars For Use With LoadWarrior-Adds 18" length For Use With LoadWarrior, Lights and 1L8Z-15266-AA Wiring Not Included

1L8Z-7855100-NA

Raised Cross Bars by Yakima Multi-Sport Ski/Snowboard Carrier, Horizontal by For Use With Factory Rack, Carries Yakima (4) Pair of Skis/(2) Snowboards (Requires 1L2Z-9855100-AA) For Use With Factory Rack, Carries (6) Pair of Skis/(4) Snowboards (Requires 1L2Z-9855100-AA) For Use With Raised Cross Bars, Carries (4) Pair of Skis/(2) Snowboards For Use With Raised Cross Bars, Carries (6) Pair of Skis/(4) Snowboards
4L2Z-7855100-BA F67Z-7855100-AA F67Z-7855100-BA F75Z-7855100-FA F75Z-7855100-GA
2004 Ford Explorer Sport Trac -- Page 4
ACCESSORY Remote Start Systems** PowerCode DESCRIPTION PART NUMBER FIT YEARS 2003-2004 2003-2004 2003-2004 2001-2001-2004 2001-2004 2003-2004 2003-2004 2003-2004 2003-2004 2003-2001-2004 2001-2004 2001-2004 2001-2004 2003-2004 2001-2004 2001-2004 2001-2004 2001-2004 2001-2004 EST INSTALL DEALER NET TIME (Hours) PRICE* 3.00 3.00 3.00 D.I.Y. 0.80 0.80 0.50 0.50 0.50 D.I.Y. D.I.Y. D.I.Y. D.I.Y. D.I.Y. D.I.Y. D.I.Y. D.I.Y. D.I.Y. D.I.Y. 1.00 0.80 0.50 0.80 D.I.Y. 2.00 D.I.Y. D.I.Y. D.I.Y. D.I.Y. $190.89 $160.59 $130.29 $21.96 $287.16 $229.10 $128.00 $25.95 $25.95 $681.75 $806.99 $806.99 $806.99 $806.99 $806.99 $806.99 $806.99 $806.99 $806.99 $788.05 $191.85 $227.20 $65.47 $15.80 $116.15 $8.32 $11.10 $91.91 $21.49 SUGG LIST PRICE* $272.70 $229.41 $186.13 $31.37 $382.88 $327.29 $272.34 $37.07 $37.07 $973.93 $1,152.84 $1,152.84 $1,152.84 $1,152.84 $1,152.84 $1,152.84 $1,152.84 $1,152.84 $1,152.84 $1,125.79 $274.07 $324.57 $93.53 $22.57 $165.93 $11.89 $15.86 $131.30 $30.70

Remote Start, Remote Keyless Entry 2W7Z-19G364-AA & Vehicle Security. Requires SecuriLock Kit 1L2Z-19G365-AB Remote Start With Keyless Entry. Requires SecuriLock Kit 1L2Z-19G365-AB 2W7Z-19G364-BA 2W7Z-19G364-CA 1L2Z-19G365-AB 3L2Z-16450-GAA 3L2Z-16450-GAB 2L2Z-9A147-AA 1L5Z-16A550-AA 1L5Z-16A550-BA V3L2Z-99501A42-AAC V3L2Z-99501A42-AAD V3L2Z-99501A42-AAE V3L2Z-99501A42-AAF V3L2Z-99501A42-AAH V3L2Z-99501A42-AAJ V3L2Z-99501A42-AAK V3L2Z-99501A42-AAL V3L2Z-99501A42-AAM V3L2Z-99501A42-AAN 1L2Z-99501A42-BAA 2L2Z-99501A42-AA 2L2Z-99501A42-BA 1L2Z-17N808-AA 3L2Z-7H332-AA 1L2Z-19D520-BA F5TZ-19F503-D F5TZ-19F503-E 2L3Z-19A282-AA F5TZ-19A282-C
Securilock Kit 3 Running Bars, Tubular Skid Plate, Fuel Tank Splash Guards, Molded Tonneau Cover By Leer Hard, Fiberglass
Remote Start Only. Requires SecuriLock Kit 1L2Z-19G365-AB Chrome Original Equipment - Med. Dk. Platinum
Securilock Interface Kit #3, Required For Remote Start Systems
Front Pair, Black, For Use Without Running Boards Rear Pair, Black Prime Red Fire Ebony Oxford White CC Dk. Pearl Blue Competition Orange Aspen Green Pueblo Gold Silver Birch Metallic CC Estate Green For Vehicles Without Bedliner With Snaps, Black Snapless, Black Class III 2000 lbs., 1-7/8" 5000 lbs., 2"
Tonneau Cover, Hard Tonneau Cover, Soft Tow Hooks Tow Kit, Neutral Trailer Hitch Trailer Hitch Balls
Trailer Hitch Drawbar, Swivel Ball Mount Quickstep, Swivel For Use With 2" Hitch Receiver 1-1/4" Drop / 4" Rise Trailer Hitch Drawbars
2004 Ford Explorer Sport Trac -- Page 5
ACCESSORY Trailer Hitch Drawbars (continued) Trailer Hitch Receiver Cover Trim Kit, B' Pillar Front & Rear, 4-Piece Set, With Vehicle Logo Vehicle Security Systems** PowerCode DESCRIPTION 0" Drop / 2-1/2" Rise With No Boundaries Logo, For 2" Receiver With Ford Logo, For 2" Receiver PART NUMBER F5TZ-19A282-D 1L2Z-17F000-BB 1L2Z-17F000-CA 2L2Z-7820049-BA Includes Vehicle Security Kit, For Use 2W7Z-19A361-BA With Factory Keyless Entry & Keyfob Includes Vehicle Security & Remote Keyless Entry. 2W7Z-19A361-CA FIT YEARS 2001-2004 2001-2004 2001-2004 2003-2004 2003-2004 2003-2004 2003-2004 EST INSTALL DEALER NET TIME (Hours) PRICE* D.I.Y. D.I.Y. D.I.Y. 0.50 2.00 2.00 2.00 $21.49 $6.35 $8.08 $85.78 $99.99 $130.29 $160.59 SUGG LIST PRICE* $30.70 $9.07 $11.54 $122.54 $142.84 $186.13 $229.41
Deluxe Vehicle Security With Remote 2W7Z-19A361-DA Keyless Entry. Includes Siren.
2004 Ford Explorer Sport Trac -- Page 6