How-to
1996 Ford Bronco Fuel Pump Replacement Through a Floor Access Panel
A fuel pump and sending unit replacement on a 1996 Ford Bronco, reached through an access panel cut into the floor rather than by dropping the tank. thebroncofanatic measured and cut the opening from steve83's specifications, pulled the pump and sender, and separated the pump from the float assembly.
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Step 1
Measure and cut an access panel in the floor above the fuel tank, about 8x11 inches. thebroncofanatic based the measurement on steve83's specs and recommends that guide as additional reference.
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Step 2
Set the cut panel aside. thebroncofanatic planned to hinge the panel and reseal it to the floor afterward.
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Step 3
Remove the gas tank ring. Keep the area around the pump clean and free of dirt before opening the tank.
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Step 4
Use a quick disconnect tool to release the fuel lines. thebroncofanatic used one bought at an auto parts store for about $5.
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Step 5
Lift the pump and sender assembly out of the tank. thebroncofanatic notes the pump had been replaced before, evident from the butt connectors on the red and black wires, with the yellow wire going to the sender.
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Step 6
Remove the three 1/4 screws holding the pump to the sender and float assembly, then separate the pump from the assembly.
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Step 7
Look closely at the wiring on the pump and sender. thebroncofanatic notes that the aftermarket pump came with decent instructions but is used on several models, so expect about 5 leftover tank gaskets and 2 clips for the older non quick disconnect fuel lines. The photos end here because the job was finished in a hurry with gas everywhere. thebroncofanatic again recommends steve83 for more information.
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