Question about 1998 Ford Windstar

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How to remove fuel pump from tank


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  • Mike Butler
    Mike Butler May 11, 2010

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If the fuel pump is not located at the front of the tank then pull the cover from off the back cargo area check to see if there is an acess plate in that area it will have 2to 5 screws and be aboutthe size of a a large coffee can if there is a plate remove it if you see the fuel tank sending unit you can acess it there, Now before removing disconnect battery posts, next make sure you are in a ventalated area with no air compressor that might come on or light sorce that might ignite the fuel vapors make sure your not in a grage with a hot water tank that operates on natural gas that might light up wile you are working on it or you will get blown up. next if you can't see the sending unit you will need to drop the tank down, if thats the case have the least amout of gas in it as possible, next look at the fuel tank and at the back or front you will see two straps holding the tank up get a deep well socket a 15 MM guessing, and an extension and ratchet, get a jack and a board about the size of the tank place the board on top of the jack and raise the jack up to hold the tank in place. spray WD40 on the two bolts going to the strap and unscrew them counter clockwise unhook the fill tube comming from the gas filling lid then lower the jack slowly until you can slide the tank down unhook the wire connectors and hoses, next slide the tank out where you can work on it there will be a ring that holds the sending unit and fuel pump on the tank the ring must be tapped counter clock wise in order to remove ring use a screwdriver, large flat tip and a hammer to tap the ring, put a rag between the screwdriver and the rign you don't want any sparks tap on one side then go to the oppisite side and tap there until you get the ring to move once it moves tap until the ring is loose, pull up on the fuel pipes on the tank and the whole unit will come out.the ring looks like this all the way around it,U U U U U U U U. When you het a new pump be sure to get a new fuel sock replace it now or you will reget it later it costs about $7.00 and buy the fuel pump from Ford, I repeat do not buy aftermarket fuel pumps I hav and have had to replace then inside a week, the fuel covers the pump and keeps it cool if you go below a 1/4 tank it will burn up the after market pumps USE ONLY FORD PARTS. It will cost you more money but it is better than doing it three times, I had a freind that had to replace his 3 times before he went to the dealer but he could remove the tank in 30 minutes (Grin) practice makes perfect. be sure to replace the O ring that goes between the fuel pump and tank and greese it up with the lube that comes with the O ring replace in reverse be sure to hook the new fuel pump up correctly the wires can be reversed on some, and it won't pump once you put it back togeter the pump will run backwards. after you have it in and the lock ring on and the tank back up you need to have two people to do the following look on the fuel rail for a valve that looks like a bicycle tire valve remove the cap and use a pen to push the shrader valve in then turn the key to the run postion only for two seconds at a time then off and then on again do this until no air comes out of the valve once you have solid fuel comming out then put cap on fill tank with gas and start engine add a bottlote of lucas gas treatment as it will save the pump and fuel injectors that are damaged by ethanol in gas put in the lucas gas treatment about every 4th tank to keep the injectors and pump from getting ruined, I would also suggest to replace the fuel filter normally located on the driver side under the driver door inside the frame, the ethanol kills the fuel filters as well, and if you want trouble free fuel pump problems buy your fuel at Shell, Texico, or Chevron do not buy ARCO gas, and buy mid grade it will give you about 4 miles more to the gallon and keep the valves and intake clean. This job from start to finsih takes about two hours pull the pump first before buying the pump and remember the parts I told you to replace it is very important so that you do not have leaks and don't destroy the new pump. Try not to let the fuel get lower than a 1/4 tank as there is not enought fuel in the tank to keep the pump cool and lubericated hope this helps. Any questions just ask, also if you have not cleaned the intake plate now would be a good time remove the hose and clean the throttle plate, buy a cleaner from GM it's called top engine cleaner use it and a tooth brush to clean the inside and outside of the throttle plate, it will improve your performance as well, there is more than that to do a top engine clean and if you want to let me know and I will give you the proceedure for that as well. good luck hope this helps. And is clear enough.

Posted on May 27, 2009


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Oct 18, 2009 | 1998 Ford Windstar

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