Repair And Fix it

Relieve the pressure in the fuel system, and disconnect the fuel tank. Clean the area around the attaching flange for the fuel pump with a shop rag. This will prevent dirt from getting into the fuel tank when you replace the fuel pump.

Turn the locking ring on the fuel pump counter-clockwise with a locking ring removal tool. Remove the locking ring from the fuel pump. Disconnect the fuel pump assembly from the fuel tank, including the bracket. Remove the gasket for the fuel pump.

Apply a thin layer of heavy grease to the new fuel pump gasket, and install it into the ring groove on the fuel tank. Place the new fuel pump assembly into position in the fuel tank. Place the locking ring onto the fuel pump, and turn it clockwise until it locks into place.

Connect the fuel tank onto the vehicle, and put at least ten gallons of gas into the fuel tank. Fix any fuel leaks, and connect a pressure gauge to the throttle body valve. Turn the ignition on for three seconds without starting the engine, and turn it off for three seconds. Repeat this at least five times to pressurize the fuel system to at least 30 pounds per square inch, or PSI.

Check the vehicle and fix any leaks. Disconnect the pressure gauge, and start the engine. Check the vehicle again, and fix any leaks.

Place a jack under the transmission. Place a block of wood on top of the jack pad, then raise the jack until the block contacts the transmission case behind the transmission oil pan. Raise the transmission slightly, just enough to take the load off the crossmember.

Place the nut splitter over the nut on the crossmember bolt. Tighten the threaded part of the nut splitter until the splitter blade squarely contacts one of the flats on the nut. Ensure the blade only bears on the nut, not the washer.

Install a ratchet and socket onto the hex head of the nut splitter. Firmly hold the splitter in place and turn the hex head using the ratchet and socket, until the nut is completely cut through and pops loose.

Back off on the splitter until it can be removed from the nut and bolt. Remove the bolts from the crossmember.

Install the new bolts and tighten them to 48 to 63 foot-pounds on 3.0 liter models, or 65 to 85 foot-pounds on 2.3 and 4.0 liter models using a foot-pound torque wrench, socket and wrench.

Open the hood of the truck and locate the two screws on the top of the trim bezel. Remove them with a Phillips screwdriver then move to the front of the bezel and locate the four screws in the face of it. Remove them with your Phillips screwdriver and set them aside.

Pull the trim bezel off the front of the truck and set it aside. There are three clips along the bottom edge of the bezel; they may require you to pull harder than you think you should but they will let go if you pull hard enough.

Locate the four screws at the corners of the headlight assembly. Remove the screws with a Phillips screwdriver then pull the headlight assembly toward you until you can reach the headlight bulb connection on the rear off the assembly.

Release the locking tab on the headlight bulb and pull the wiring harness connector off the bulb. Set the harness aside and remove the headlight assembly off the truck.

Loosen the cap on the fuel tank and remove the air filter. Disconnect the cable from the negative battery terminal. Remove the valve cap from the pressure relief valve on the fuel rail. Connect fuel pressure gauge tool T80L-9974-A to the pressure relief valve. Open the pressure relief valve to relieve the pressure in the fuel system. Disconnect the fuel pressure gauge and replace the valve cap.

Drain the fuel from the fuel tank. Support the fuel tank with jack stands. Release the clamp on the fuel tanks fill pipe. Disconnect the bolts for the skid plate and remove the skid plate and its brackets from the fuel tank. Disconnect the bolts for the front and rear straps of the fuel tank and remove the straps. Release the clamp for the fuel sender units fuel hose. Remove the fuel lines from the fuel sender unit. Lower the tank from the Ranger with the floor jacks. Remove the shield from the fuel tank.

Detach the electrical connector from the fuel system sender unit. Clean the fuel tank around the fuel sender unit with a shop rag. Turn the locking ring on the fuel sender unit counterclockwise with a hammer and brass drift. Remove the locking ring from the fuel sender unit and pull the fuel sender unit from the fuel tank. Discard the sealing gasket. Detach the fuel pump from the fuel sender unit.

Insert the new fuel pump into the fuel sender unit. Put a new sealing gasket on the fuel tank. Place the fuel sender unit into the fuel tank and align the fuel senders tabs with the fuel tanks slots. Attach the locking ring to the fuel sending unit and turn it clockwise until the ring tab is against the stop. Attach the electrical connector for the fuel sender unit.

Reinstall the fuel tank. Reconnect the negative cable on the battery. Turn the ignition on for five seconds, then turn it off. Repeat at least five times to pressurize the fuel system. Start the engine and check for fuel leaks.