Gas Tank On Ford Explorer – Capacity, Troubleshooting, And Repair
The fuel system of your Ford Explorer is the lifeline of your vehicle, dictating how far you can travel and how safely you get there. This comprehensive guide covers fuel tank capacities across different generations, common diagnostic issues like EVAP leaks, and a detailed walkthrough for safely performing a replacement or repair.
Whether you are preparing for a cross-country road trip or tackling a rugged off-road trail, you rely on your vehicle’s fuel system to perform flawlessly. We have all experienced that moment of worry when the fuel gauge fluctuates or a faint scent of gasoline lingers in the garage.
I have spent years diagnosing and repairing these SUVs, and I know that the gas tank on ford explorer models can vary significantly depending on the production year and trim level. Understanding these nuances is the first step toward maintaining a reliable and safe vehicle for your family.
In this guide, I will share professional insights into troubleshooting common fuel delivery issues and provide a clear roadmap for DIY maintenance. My goal is to empower you with the technical knowledge needed to handle fuel system repairs with the precision of an experienced technician.
Understanding the Gas Tank on Ford Explorer Generations
The Ford Explorer has evolved through six generations, and with those changes came different fuel tank designs and materials. Early models often featured steel tanks, while modern iterations utilize high-density polyethylene (HDPE) for weight reduction and corrosion resistance.
The capacity of the gas tank on ford explorer typically ranges between 17 and 21 gallons. For example, the fifth-generation (2011–2019) models usually carry an 18.6-gallon tank, while the sixth-generation (2020–present) often features a 17.9-gallon or 20.2-gallon tank depending on the drivetrain.
Material Evolution and Durability
Older steel tanks were prone to internal rusting if left sitting with low fuel levels for extended periods. This rust could eventually clog the fuel strainers or damage the fuel injectors, leading to poor engine performance.
Modern plastic tanks are virtually immune to rust, making them much more durable for long-term ownership. However, they are more susceptible to structural damage from sharp debris or rocks if you frequently take your Explorer off-road without proper protection.
Location and Accessibility
In most Explorer generations, the tank is located mid-ship, tucked safely between the frame rails to protect it during a collision. Unfortunately, Ford rarely includes an access panel under the rear seats, meaning you must drop the entire tank to service the fuel pump.
Common Issues and Diagnostic Steps
One of the most frequent complaints regarding the gas tank on ford explorer involves the Evaporative Emission (EVAP) system. If your “Check Engine” light is on with codes like P0455 or P0442, you likely have a leak in the fuel vapor recovery circuit.
Start your diagnosis by inspecting the filler neck, which is the metal tube connecting the gas cap area to the tank. In salt-belt states, these tubes often corrode, creating pinhole leaks that trigger emission warnings and cause a noticeable fuel smell.
Identifying Fuel Pump Failure
If your Explorer cranks but refuses to start, or if it stumbles under heavy acceleration, your fuel pump may be failing. Listen for a faint humming sound from the rear of the vehicle for two seconds when you first turn the ignition to the “On” position.
If you hear silence, the pump or its electrical relay may be dead. Use a fuel pressure gauge at the engine’s fuel rail to verify if the pump is delivering the required PSI (usually between 35 and 65 PSI depending on the engine type).
Addressing Faulty Fuel Gauges
A “ghosting” fuel gauge that shows full one minute and empty the next usually points to a worn sending unit. This component uses a float and a variable resistor inside the tank to communicate the fuel level to your dashboard.
Over time, sulfur deposits from low-quality gasoline can build up on the resistor’s contact points. Using a high-quality fuel system cleaner can sometimes resolve minor erratic readings, but a complete failure requires replacing the sending unit assembly.
The Step-by-Step Guide to Dropping the Tank
Dropping the gas tank on ford explorer is a significant task that requires patience and strict adherence to safety protocols. Gasoline is highly flammable, and the vapors are even more dangerous, so always work in a well-ventilated area away from pilot lights.
Before you begin, try to run the fuel level as low as possible. A full 20-gallon tank weighs roughly 120 pounds, making it incredibly difficult to balance on a floor jack during the removal process.
Preparation and Safety Measures
- Disconnect the negative battery terminal to prevent any accidental sparks.
- Lift the rear of the vehicle and support it securely with heavy-duty jack stands on the frame rails.
- Use a manual siphon pump to remove any remaining fuel into approved gasoline containers.
Disconnecting Lines and Straps
Locate the fuel filler hose and the smaller vent hose attached to the tank. Loosen the hose clamps and carefully wiggle the hoses off the tank’s plastic nipples, being careful not to crack the plastic.
Support the center of the tank with a floor jack and a wide piece of wood to distribute the weight. Remove the bolts securing the metal straps, then slowly lower the jack just enough to reach the electrical connectors and quick-connect fuel lines on top.
Using Disconnect Tools
Ford uses specific quick-connect fittings for the high-pressure fuel lines. You will need a set of plastic or metal fuel line disconnect tools to release the internal springs without damaging the delicate plastic connectors.
Off-Road Considerations and Protection
For the off-road enthusiast, the gas tank on ford explorer is a vulnerable component during rock crawling or trail riding. A single sharp rock can puncture a plastic tank, leaving you stranded miles from the nearest paved road.
If you plan on taking your Explorer into the backcountry, I highly recommend installing an aftermarket skid plate. These shields are typically made from 3/16-inch steel or aluminum and bolt directly to the frame to provide a “sliding” surface over obstacles.
Inspecting for Trail Damage
After every off-road excursion, crawl under your vehicle and inspect the tank straps and the bottom of the tank for deep gouges or cracks. Even a small stress fracture can expand over time due to the pressure changes inside the fuel system.
Pay close attention to the vapor canister, which is often mounted near the tank. This plastic box is part of the EVAP system and is easily cracked by flying debris, leading to immediate “Check Engine” lights and potential vacuum leaks.
Replacing the Fuel Pump and Sending Unit
Once the tank is on the ground, you have clear access to the fuel pump module. Before removing it, use compressed air or a brush to clean the top of the tank thoroughly to prevent dirt from falling inside.
Most Explorers use a locking ring to hold the pump in place. While you can sometimes use a hammer and a brass drift (non-sparking) to rotate the ring, a dedicated fuel pump lock ring tool makes the job much safer and faster.
Installing the New Module
When installing the new pump, ensure the rubber O-ring is seated perfectly in the groove. A misaligned seal is the most common cause of “Large EVAP Leak” codes immediately following a fuel pump replacement.
Check the electrical connector for any signs of melting or corrosion. Ford fuel pumps draw significant amperage, and a loose connection can cause the wires to overheat, eventually melting the plastic housing and causing a failure.
Testing Before Reinstallation
Before you bolt the tank back into the vehicle, I recommend reconnecting the electrical plug and the battery briefly to “prime” the pump. If you hear the pump run and the gauge moves correctly, you can proceed with the heavy lifting of reinstallation.
Maintenance Tips for Longevity
Maintaining the gas tank on ford explorer involves more than just filling it with fuel. One of the best habits you can develop is avoiding the “Low Fuel” warning light; the fuel in the tank actually acts as a coolant for the electric pump.
Consistently running on empty allows the pump to run hot, which significantly shortens its lifespan. Aim to keep at least a quarter tank of gas at all times to ensure the pump remains submerged and cool during operation.
- Use Quality Fuel: Stick to Top Tier gasoline brands to minimize carbon and sulfur buildup on the sending unit.
- Check the Gas Cap: A worn rubber seal on the cap is the #1 cause of EVAP codes; replace it every 50,000 miles as preventative maintenance.
- Inspect Straps: During oil changes, check the metal tank straps for heavy rust, especially if you live in a snowy climate.
Frequently Asked Questions About Gas Tank on Ford Explorer
How many gallons does a Ford Explorer gas tank hold?
Most modern Ford Explorers hold between 17.9 and 20.2 gallons. Older models from the early 2000s typically featured a 21-gallon tank, while the newest hybrids may have slightly smaller capacities to accommodate the battery pack.
Why do I smell gas around my Ford Explorer?
A gas smell is often caused by a leaking filler neck or a cracked EVAP canister. If the smell is strongest near the rear wheel well, inspect the metal neck for rust or the plastic tank for signs of weeping fuel.
Can I replace the fuel pump without removing the gas tank?
Unfortunately, most Ford Explorer models do not have an access hatch under the rear seat. This means you must support the vehicle on stands and lower the tank to reach the fuel pump module located on top.
What does a P0456 code mean on my Explorer?
This code indicates a very small EVAP leak. It is often caused by a loose gas cap, a faulty vent valve, or a tiny pinhole in one of the plastic vapor lines running along the frame rail.
Conclusion
Taking care of the gas tank on ford explorer is essential for maintaining the vehicle’s efficiency and your peace of mind. By understanding the common failure points like the filler neck and the fuel pump, you can save thousands of dollars in shop labor costs over the life of your SUV.
Always prioritize safety when working with fuel systems. Use the right tools, work in a ventilated space, and never hesitate to call a certified mechanic if you encounter a leak or electrical issue that feels beyond your current DIY skill level.
Keep your tank protected, your fuel clean, and your seals tight. Stay safe on the trails and enjoy the many miles of adventure your Ford Explorer has to offer!
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