How do you change a fuel pump on a Freestar - Monterey?

Answer 1

As is typical of many Ford products, the gas tank is going to have to be removed to service the fuel pump. (wish they would use through-the-floor access plates more often - like the Contour... End of editorial commentary...)

Signs of a bad / failed pump:

* Car cranks - no fire

* Fuel filter is fine - check that first

* You don't hear the pump run for a few seconds when you first turn the key to the run position - put your head right by the tank to double check you do/don't hear it initialize

* Car runs like it's starving for gas - insufficient fuel pressure. Vehicle can actually run, but as soon as you push the gas pedal, it starts hesitating - bucking.

NOTE: a fuel pressure gauge comes in handy - not exactly sure of the pressure requirement on this one, but 25 lbs or more at idle, 30-40 at higher rpms is typical.

* Pumps & assembly prices range from $140-300+

I have had good experience with used pumps out of a salvage yard - a cheap way to get back on the road.

Dropping the tank is pretty straight-forward, and all the normal warnings apply:

* No SMOKING (just had to say it out loud ya know...)

* Drain as much of the fuel out as you can get - siphon hose, hand pump, etc.

* A couple pair of hands to help lower / raise the tank are best - a real bear when trying this all by yourself.

* Relive the fuel pressure before disconnecting lines - trip the fuel shutoff switch in the back corner by the tire jack, or pull the fuel pump fuse/relay - run the engine until it dies off.

* The fuel tank has a composite protective shield mounted with the support straps and retainers on the right side of the tank. Make sure the shield is correctly installed when installing the tank.

# Disconnect the negative battery cable

# Remove the fuel filler pipe

# Support the fuel tank

# Disconnect the electrical connectors and fuel line fittings

# Disconnect the retaining straps and lower the tank

# Clean the area around the pump access opening

# Turn the locking ring counterclockwise to remove

# Lift out the fuel pump

If you're replacing just the pump - follow the product instructions (IF provided) for switching the pump on the assembly.

Be careful of the float arm - don't want to be bending it - it's always falling up & down to be perfectly in your way.

To install: # Use a new gasket - grease it up a bit to help hold it in place

# Put the pump in and tighten the retaining/lock ring (60 ft lbs)

# Re-install the tank - hopefully you have that extra pair of hands to help with the balancing act

# Reconnect fill tube, wire harness, and fuel line. Some of these may easier done before lifting the tank into its final mounting position

# Time for some gas and check everything for leaks

# Start the engine and check again for leaks