Written by: Waffen
Discussion thread: http://www.ranger-forums.com/forum2/...ad.php?t=81181
I replaced the fuel pump on my 1999 4.0 OHV today. I'll do my best to provide a little background on the issue.
1/2" Socket Wrench
3/8" Socket Wrench
Torx T-45 & T-55 bits
Ford Fuel Line disconnect tool (1/4th & 3/4ths)
Punch or long screw driver
Remove the tailgate. Unbolt the two Torx-T45 bolts from the tailgate support and remote the tailgate.
Unhook the tail lights from the wiring harness. Crawl under the truck and look under the rear bumper.
Remove the bed. If you have a bed liner you'll have to remove it first. Make sure to unhook the 3 6mm bolts that secure the fuel filler neck.
There are 6 bolts that secure the body to the frame. The bolts have a Torx T-55 bolt head. I soaked these bolts in PB Blaster 1 day before removal and I believe this helped. The 1/2" impact made short work of this.
Tip: Don't expect your wife to be able to easily lift one side of the bed. My truck is body lifted so it made it harder for short people.
Disconnect the battery.
Disconnect the 1/4" and 3/4" fuel lines. You will need the special ford "spring lock"
Disconnect the fuel pump from the wiring harness.
Unscrew the retaining ring from the fuel tank. I used a steel punch and a 3lb hammer. I was very careful not to create any sparks. This slowly allowed the ring to come loose.
Carefully remove the fuel pump and fuel level sensor.
There is one retaining clip that is screwed down that secures the pump in place. The screw that hold this down also secures the end of the return line. Remove this screw and remove the retaining clip.
Remove the one hose connected to the fuel pump, and remove the electrical connection from the wiring harness. The fuel pump is now free.
Step 11: Graft the new pump in place of the old and reassemble in reverse order.
I know the pics aren't the best but I hope they help. I wish I had them when I was doing mine.