How to remove fuel pump/drop tank in 03
This applies to a 2003 Expy. Should apply to 04-06 as well, but don't guarantee anything. As my siggy says, I'm not responsible if you break something. For educational purposes only
-------------------------------
1. Release the fuel system pressure.
2. Drain the fuel tank.
3. Disconnect the vapor hoses at the rear of the fuel tank.
4. If equipped, remove the fuel tank skid plate.
5. NOTE: The 4.6L and 5.4L (2V) engines are equipped with returnless fuel systems. The 5.4L 4V engine is equipped with a return-type fuel system.
Disconnect the vapor hose and the fuel hose(s) forward of the fuel tank.
6. CAUTION: Do not support the fuel tank directly beneath the fuel pump mounting area. Damage to the fuel pump assembly can occur.
Position a suitable jack under the fuel tank.
7. NOTE: The location of the fuel vent hose is critical to fuel system operation. Note the routing of the fuel vent hose at this time.
Remove the fuel tank front and rear support straps and lower the front of the fuel tank approximately 25 mm (1 in).
8. NOTE: RH shown, LH similar.
Remove the rear LH and RH sway bar bracket nuts and lower the sway bar.
9. Remove the rear driveshaft.
10. Loosen the clamp and disconnect the vent hose from the fuel tank vent spout.
11. Disconnect the fuel pump electrical connector.
12. Remove the fuel tank from the vehicle.
This applies to a 2003 Expy. Should apply to 04-06 as well, but don't guarantee anything. As my siggy says, I'm not responsible if you break something. For educational purposes only
-------------------------------
1. Release the fuel system pressure.
2. Drain the fuel tank.
3. Disconnect the vapor hoses at the rear of the fuel tank.
4. If equipped, remove the fuel tank skid plate.
5. NOTE: The 4.6L and 5.4L (2V) engines are equipped with returnless fuel systems. The 5.4L 4V engine is equipped with a return-type fuel system.
Disconnect the vapor hose and the fuel hose(s) forward of the fuel tank.
6. CAUTION: Do not support the fuel tank directly beneath the fuel pump mounting area. Damage to the fuel pump assembly can occur.
Position a suitable jack under the fuel tank.
7. NOTE: The location of the fuel vent hose is critical to fuel system operation. Note the routing of the fuel vent hose at this time.
Remove the fuel tank front and rear support straps and lower the front of the fuel tank approximately 25 mm (1 in).
8. NOTE: RH shown, LH similar.
Remove the rear LH and RH sway bar bracket nuts and lower the sway bar.
9. Remove the rear driveshaft.
10. Loosen the clamp and disconnect the vent hose from the fuel tank vent spout.
11. Disconnect the fuel pump electrical connector.
12. Remove the fuel tank from the vehicle.
Last edited: