How to Remove the Fuel Tank on a 2002 Expedition

The 2002 Ford Expedition was available in the XLT, XLT 4x4, Eddie Bauer and Eddie Bauer 4x4 models. The base model XLT was equipped with a 4.6-liter V-8 engine. A 5.4-liter V-8 engine was available as an option. The fuel tank on the 2002 Expedition is located on the driver's side of the truck, parallel to the front-to-rear frame of the truck. Fuel tanks are sometimes removed to repair holes or to replace the fuel tank. Removal of the tank is necessary to access the top-mounted fuel pump on the 2002 Expedition.

Instructions

1

Open the hood of the Expedition. Remove the cap from the fuel rail pressure testing port. Wrap a rag around the tip of a screwdriver. Insert the wrapped tip of the screwdriver into the pressure testing port carefully. Depress the center pin in the port slightly to release the fuel pressure while allowing the rag to soak up any fuel that is expelled.

2

Open the rear hatch on the Expedition, and turn off the air suspension switch in the rear luggage area. Raise the rear of the expedition with a jack. Place jack stands beneath the rear axle housing, near both outer ends. Lower the Expedition onto the jack stands.

3

Place your jack directly beneath the fuel tank. Insert a wood plank on top of the jack. Raise the jack and the plank of wood up to the bottom of the fuel tank so the wood runs parallel to the length of the tank. Do not press upward on the bottom of the tank with the jack. Remove the fuel tank shield, if equipped, with a ratchet and socket.

4

Slide out from beneath the vehicle and proceed to the driver's side of the Expedition just in front of the rear wheel. Lie beneath the side of the truck and slide yourself in position to access the fuel filler neck and the vapor tube. Remove any hose clamps from the filler neck and vapor tube with a ratchet and socket. Disconnect the two parts from the fuel tank completely. Move back to beneath the rear of the Expedition when you have removed the filler neck and vapor tube.

5

Remove the fuel strap bolts with a ratchet and socket. Lower the straps from the tank and move them to the forward- and rear-facing sides of the tank. Lower the fuel tank halfway between the ground and the bottom of the truck, using the release lever or knob on the jack. Maintain one hand on the fuel tank to help balance the tank as it drops from the truck.

6

Remove the fuel lines from the top of the fuel tank, using a quick disconnect removal tool. Remove all evap lines if are working on a standard gasoline-ueled Expedition. Lower the fuel tank completely on the jack when all of the connections have been removed.

7

Guide the fuel tank onto a large piece of cardboard rather than setting the tank directly onto the ground. Loose gravel, cement and asphalt can all cause static electrical sparks between the ground and the fuel tank. Slide the cardboard out from beneath the rear of the truck with the fuel tank on top of the cardboard. If you are replacing the fuel tank or any of its components, do so at this time. If you are moving the fuel pump, note the position of the pump in the old tank to match the position in the new tank.

8

Installation of the fuel tank is the exact opposite of the removal process. Tighten the fuel tubes on top of the tank snug before raising the tank to the bottom of the truck. Tighten the fuel tank straps to between 33 and 48 foot-pounds with a 1/2-inch-drive torque wrench and socket. Install the fuel filler neck and vapor tube from the driver's side of the truck and tighten the clamps snug with a ratchet and socket. Install the tank shield at this time, and tighten the mounting bolts between 33 and 48 foot-pounds.

9

Raise the Expedition off the jack stands and remove the stands from beneath the truck. Add at least 5-gallons of fresh gasoline to the fuel tank through the filler neck. Install the fuel filler cap and tighten it once you have added new fuel. Proceed to the rear of the Expedition and turn the air ride suspension switch back to the "On" position.

10

Sit in the driver's seat of the Expedition. Turn the ignition key to the "II" or accessories position without starting the truck. Turn the key to the "Off" position. Repeat this key turning process three to five times, to allow the fuel pump to prime the fuel system with fresh fuel and fuel pressure. If you hear a hissing or dripping sound at all during this process, turn the ignition key off and remove it from the ignition. Recheck your line fittings throughout the entire fuel tank to ensure you have no leaks.