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The average cost for a Ford Explorer Sport Trac fuel pump replacement is between $663 and $707. Labor costs are estimated between $171 and $215 while parts are priced at $492. This range does not include taxes and fees, and does not factor in your specific model year or unique location.
Make sure battery has a full charge and battery connections all good. Use a digital multi meter across battery posts, have helper turn key to crank, how far does the voltage drop? Generally it shouldn't drop below 10 volts, that spec is subjective, but, if the reading drops way down there, I'd check the battery and connections.
You could check voltage at inertia switch. That might give you an idea if the problem is before the inertia switch or after?
Fig. Fuel pump flange bolt torque sequence-2002 Explorer and Mountaineer and Sport-Trac Sport Built Before 03/2002
Before servicing the vehicle, please familiarize yourself with safety procedures.
Disconnect the battery ground cable.
Relieve the fuel system pressure.
Drain the fuel tank.
4WD vehicle
Remove the fuel tank skid plate bolts.
Remove the fuel tank skid plate rear left bolt.
Remove the fuel tank skid plate rear right bolt and lower the fuel tank skid plate.
All vehicles
Use a suitable jack to support the fuel tank.
Remove the vent hose.
Remove the bolt and reposition the fuel tank support strap.
Remove the support bolts and push the fuel tank back until the lip clears the support bracket.
Lower the fuel tank just enough to expose the fuel lines and the fuel tank transducer connector.
Disconnect the fuel line and the vapor line.
Disconnect the fuel tank electrical supply connector near the frame rail. Lower the fuel tank.
Clean the area around the fuel pump assembly mounting flange.
Disconnect the electrical connector from the fuel pressure transducer.
WARNING
The fuel pump assembly must be handled carefully to avoid damage to the float arm and the filter.
Remove the fuel pump mounting bolts and remove the fuel pump assembly.
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