How to Replace an Explorer's Gas Tank Filler Neck

Written by chris moore
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How to Replace an Explorer's Gas Tank Filler Neck
(pumping gas image by Mat Hayward from Fotolia.com)

The Ford Explorer uses a fuel tank where the filler neck is not a fixed part of it. This makes it simpler if you have to replace a punctured or otherwise damaged filler neck. It is possible to remove and replace the pipe without draining or removing the tank itself. You will, however, need to work from both underneath and outside the vehicle. This process can vary depending on the exact year of your Ford Explorer.

Skill level:
Moderately Challenging

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Things you need

  • Floor jack
  • Jack stands
  • Ratchet wrench

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Instructions

  1. 1

    Raise the hood and open the fuse box. Start the engine, remove the fuel pump relay (usually the second relay from the left on the bottom row) and wait for the engine to stall out. Reconnect the relay

  2. 2

    Raise the vehicle's rear end and support it on jack stands. Unbolt and remove the transfer case skid plate and the filler pipe's heat shield (usually equipped on 2006 and later models).

  3. 3

    Loosen the hose clamp at the connection of the filler pipe and the fuel tank using your screwdriver and disconnect the pipe from the tank. Disconnect the vapour tube at its hose clamp.

  4. 4

    Open the fuel door on the side of the vehicle and remove the screws fastening the spout to the flange; they usually take a 1/4-inch drive ratchet. Remove the spout from the flange.

  5. 5

    Pull the filler neck out through the hole from the outside of the truck.

  6. 6

    Insert the replacement neck into and through the filler hole in the vehicle and reconnect the spout with its fasteners.

  7. 7

    Connect the filler pipe to the tank and vent neck with their hose clamps.

  8. 8

    Reconnect the heat shield and skid plate and lower the vehicle.

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