Where is and how to change the fuel pump on a Taurus - Sable?

For the risk-taker It is possible to cut your very own access hole in the floor to avoid having to drop the gas tank. I know cause I did it! See "Related Questions" below for more See photos in "Related Links" below Before getting started Some car makers provide an access panel, normally located either under the trunk mat or the rear seat, so that the in-tank electric fuel pump can be accessed Ford does not do this on the Mercury Sable.To replace the 1996 Mercury Sable fuel pump, the entire gas tank must be removed from the vehicle.

To do this, the vehicle must be raised so that the bottom of the gas tank is at least 18 to 24 inches off of a solid surface so that the tank can be dropped and removed Before attempting to remove the gas tank, the fuel pressure in the gas lines and intake manifold must be relieved, and all gasoline removed from the gas tank. Since there is no drain plug, and the fuel spout, or filler tube is convoluted and twisted from the gas cap to the bottom of the tank, a 1/4" to 3/8" eight foot long siphon tube will be needed to remove most of the gas On a vehicle that is 12 years old, many, or all of the plastic retainer clips and fittings on the rubber and metal gas lines will be brittle, hard to remove, and will break and must be replaced. Some of the rubbers hoses will also be "welded" to the metal pipes and fittings and might also need replacement, after being pried and twisted off of their fittings All rubber gaskets, or "O" rings on the fuel lines will need to be replaced upon assembly once the gas lines have been disconnected because the older "O" rings will have expanded once exposed to air and will leak after assembly Once the gas tank is drained and removed, and the fuel pump is accessible to be replaced you can assume that the entire in-tank fuel pump assembly, and not just the electric fuel pump itself, will need to be replaced.

This is because all of the lines, fittings, and housing holding or connected to the electric fuel pump are plastic and will be brittle and prone to break upon removal or installation Since removing, and replacing the gas tank on the vehicle requires special tools and jacks and jack stands, and could involve danger of an explosion, the subject should be studied very carefully before any removal is attempted. Either the Chilton or Haynes automotive manuals will provide about 90% of the knowledge needed to do the removal and replacement The other 10% will be learned as you try to follow the Chilton or Haynes instructions Procedures This repair is not a quick or easy one. The less fuel in the tank the easier it will be.

I wouldn't recommend even attempting this repair with more than 1/4 of a tank of fuel, and you really need a lift to make this repair, especially if there is any weight to the tank whatsoever. And always perform fuel related repairs in a well ventilated area You can buy just the pump, but I would recommend going ahead and replacing the entire assembly. The cost is $220-$260 for Carter or Airtex brands 1.

Disconnect the cable from the negative battery post 2. Locate the fill tube (hard tube attached at the rear of the tank which goes to the gas cap) and remove the hose clamp at the end of the fill tube.Do not remove the clamp at the tank 3. DO NOT PERFORM THIS STEP WITHOUT HAVING THE TANK SUPPORTED!

The tank is attached by two metal straps which are bolted at the rear of the tank. When you support the tank, do not obstruct the straps, they will need to fall freely when you remove them. The straps are attached by one bolt each at the rear of the tank.

Remove the bolts and let the straps fall away from the tank.IT IS EXTREMELY IMPORTANT THAT YOU DO NOT BEND THE STRAPS! They must retain their shape to fit back on the tank correctly.

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