August 2026

1996 Ford Explorer Fuel Pump Fuse Location: The Complete Guide to Finding and Fixing It

The bottom line: If your 1996 Ford Explorer cranks but won't start, the fuel pump fuse is the first thing you should check. The fuel pump fuse is a 20-amp maxi-fuse located in the Power Distribution Box under the hood, near the brake fluid reservoir. It is the 6th maxi-fuse from the firewall end, in the first row from the driver's side. The fuel pump relay is also in the same box, one of the large relays in the second row from the driver's side, 2nd from the front.

This guide will walk you through everything you need to know about locating, testing, and replacing the fuel pump fuse on your 1996 Ford Explorer. We'll also cover related components like the fuel pump relay and the inertia switch, so you can get your truck running again without spending a dime at a mechanic.

1. Where Is the Fuel Pump Fuse on a 1996 Ford Explorer?

The 1996 Ford Explorer has two main fuse boxes: one inside the passenger compartment and one under the hood. The fuel pump fuse is not in the cabin fuse panel. It is located in the Power Distribution Box (PDB) under the hood.

Exact location of the Power Distribution Box:

Open the hood of your Explorer
Look near the brake fluid reservoir on the driver's side
You will find a black plastic box with a removable cover
This is the Power Distribution Box

Identifying the fuel pump fuse:

Remove the cover of the Power Distribution Box
Look for a 20-amp maxi-fuse in the first row from the driver's side
It is the 6th fuse from the firewall end (toward the windshield)
On the fuse box diagram, this fuse is labeled as "Fuel system, anti-theft system" or simply "Fuel Pump"

Important note: The 1996 Ford Explorer uses a slightly different layout than later models. If you have a 1996 model with the Electronic Automatic Temperature Control (EATC) system, the fuel pump fuse is still a 20-amp maxi-fuse in the same Power Distribution Box, but it may be labeled differently on the diagram.

2. Identifying the Correct Fuse: What to Look For

The 1996 Ford Explorer fuel pump fuse is a 20-amp maxi-fuse. Maxi-fuses are larger than standard mini-fuses and are typically yellow in color.

How to tell if the fuse is blown:

Open the Power Distribution Box cover
Look for a fuse with a broken or melted metal strip visible through the clear plastic casing
A blown fuse will have a visible gap in the metal band

Checking the fuse with a test light or multimeter:

Set your multimeter to continuity mode or resistance mode
Touch the probes to the two metal prongs on the top of the fuse
If you hear a beep or see a low resistance reading, the fuse is good
If there is no continuity, the fuse is blown and needs replacement

Never use a higher amperage fuse: If the fuse is blown, replace it with another 20-amp maxi-fuse only. Using a higher amperage fuse can cause wiring damage or a fire. If the new fuse blows immediately, there is a short circuit in the fuel pump circuit that needs to be diagnosed.

3. Where Is the Fuel Pump Relay on a 1996 Ford Explorer?

The fuel pump relay is also located in the Power Distribution Box under the hood. It is one of the larger relays in the box.

Locating the fuel pump relay:

Open the Power Distribution Box
Look for the second row of relays from the driver's side
The fuel pump relay is the 2nd large relay from the front of the box (toward the grille)
It may be labeled "Fuel Pump Relay" on the underside of the cover

Testing the fuel pump relay:

The relay is a square or rectangular component with four or five pins
You can swap it with a known good relay of the same type (like the horn relay or wiper relay) to see if the problem moves
If the fuel pump starts working after swapping, the relay is bad

When to suspect the relay:

If the fuel pump fuse is good but the pump still doesn't run
If you hear a clicking sound from the relay when turning the key but the pump doesn't prime
If the relay feels hot to the touch or shows signs of burning

4. What Does the Fuel Pump Fuse Power?

The 20-amp fuel pump fuse in the 1996 Ford Explorer does not only power the fuel pump. It also protects several other critical systems. Specifically, the fuse labeled "Fuel system, anti-theft system" powers:

The fuel pump relay coil
The fuel pump itself (through the relay contacts)
The anti-theft system
The Powertrain Control Module (PCM) memory circuit

This is an important distinction because if the fuse blows, you will lose power to multiple systems. The engine will crank but will not start because the PCM may also lose power.

Fuse #13 on some models: On some 1996 Ford Explorer configurations, the fuel pump system is powered by fuse #13 in the Power Distribution Box. This is a 30-amp fuse that also feeds the PCM power relay, fuel injectors, idle air control, and other critical engine sensors.

5. The Fuel Pump Inertia Switch: What You Need to Know

The 1996 Ford Explorer has a safety feature called the inertia switch (also called the fuel shut-off switch). This switch is designed to cut power to the fuel pump in the event of a collision.

Location of the inertia switch:

The inertia switch is in the front passenger footwell
Look in the corner, above the carpet and below the dashboard
It is a small, usually red, button-style switch

How to reset the inertia switch:

Press the button on top of the switch until you feel it click
Try starting the engine
If the engine starts, the switch had tripped and has now been reset

When to check the inertia switch:

If you have recently been in an accident or hit a large pothole
If the fuel pump fuse is good but the pump still doesn't run
If the vehicle was running fine and then suddenly died

6. Step-by-Step: How to Check the Fuel Pump Fuse on a 1996 Ford Explorer

Follow these steps to check the fuel pump fuse on your 1996 Ford Explorer:

Step 1: Park the vehicle safely

Park on a level surface
Turn off the engine and remove the key
Engage the parking brake

Step 2: Disconnect the battery

Always disconnect the negative battery terminal before working on the Power Distribution Box
This prevents accidental short circuits and electrical shocks

Step 3: Locate the Power Distribution Box

Open the hood
Find the black plastic box near the brake fluid reservoir on the driver's side

Step 4: Open the box

Press the tabs on the sides of the cover to release it
Lift the cover off and set it aside

Step 5: Find the fuel pump fuse

Look at the diagram on the underside of the cover (if available)
Locate the 20-amp maxi-fuse in the first row from the driver's side, 6th from the firewall

Step 6: Inspect the fuse

Look through the clear plastic casing
Check for a broken or melted metal strip
If the fuse looks blown, proceed to Step 7

Step 7: Test the fuse with a multimeter (optional)

Set your multimeter to continuity mode
Touch the probes to the two metal prongs on the top of the fuse
A good fuse will show continuity; a blown fuse will not

Step 8: Replace the fuse if needed

Use a fuse puller or needle-nose pliers to remove the fuse
Replace it with a new 20-amp maxi-fuse only
Do not use a higher amperage fuse

Step 9: Reconnect the battery

Reconnect the negative battery terminal
Try starting the engine

Step 10: Test the fuel pump

Turn the key to the "ON" position (not start)
Listen for a humming sound from the rear of the vehicle
The fuel pump should prime for 2-3 seconds

7. Why Does the Fuel Pump Fuse Keep Blowing?

If you replace the fuel pump fuse and it blows again immediately or shortly after, there is a deeper problem. A blown fuse is a symptom, not the root cause. Common causes include:

Short circuit in the fuel pump wiring:

Wires running to the fuel pump can chafe against the frame or body
This is especially common on older vehicles where wire insulation has deteriorated
Check the wiring harness near the fuel tank for damage

Faulty fuel pump:

A failing fuel pump can draw too much current, causing the fuse to blow
The pump may have internal short circuits
This is a common failure mode on 1996 Ford Explorers

Faulty fuel pump relay:

A stuck relay can keep the fuel pump running continuously
This can overload the circuit and blow the fuse
Replace the relay if you suspect it is stuck

Short circuit in another component:

The fuel pump fuse also powers the PCM and anti-theft system
A short in any of these components can cause the fuse to blow
Check the PCM and associated wiring for damage

Diagnosing the cause:

Remove the fuel pump relay
Disconnect the PCM and related sensors
Install a new fuse
If the fuse does not blow, reconnect components one at a time until the fuse blows again
This will identify the faulty component

8. Common Symptoms of a Blown Fuel Pump Fuse

Knowing the symptoms of a blown fuel pump fuse can save you time and money. Here are the most common signs:

Engine cranks but won't start:

This is the most obvious symptom
The starter motor turns the engine over, but the engine never fires
The fuel pump cannot deliver fuel to the engine

No fuel pump priming sound:

When you turn the key to the "ON" position, you should hear a 2-3 second hum from the rear of the vehicle
If you hear nothing, the fuel pump is not getting power

Check Engine Light comes on:

The PCM may detect a loss of fuel pressure
This can trigger a Check Engine Light

Vehicle stalls while driving:

If the fuse blows while driving, the engine will lose power and stall
This is a safety hazard, so address the issue immediately

No power to other components:

Since the fuel pump fuse also powers the PCM and anti-theft system, other systems may not work
The radio, interior lights, or other accessories may stop working

9. What to Do If the Fuse and Relay Are Good but the Pump Still Doesn't Work

If you have checked the fuel pump fuse, the fuel pump relay, and the inertia switch, and all are good, the problem may be deeper. Here are the next steps:

Check for power at the fuel pump connector:

Access the fuel pump by removing the rear seat or trunk panel
Locate the electrical connector at the top of the fuel tank
Use a multimeter set to DC voltage
With the ignition in the "ON" position, check for 12 volts at the connector
If there is no power, the problem is in the wiring between the relay and the pump
If there is power, the fuel pump itself is likely faulty

Test the fuel pump ground:

A poor ground connection can prevent the fuel pump from running
Check the ground wire at the fuel pump connector
Ensure the ground connection is clean and tight

Check the wiring harness:

Inspect the wiring from the Power Distribution Box to the fuel pump
Look for damaged, corroded, or chafed wires
Pay special attention to areas near the frame and body

Replace the fuel pump:

If you have power at the connector but the pump does not run, the pump is likely faulty
The fuel pump is located inside the fuel tank and requires dropping the tank to replace
This is a significant job, so consider having a professional do it

10. Preventing Future Fuel Pump Fuse Issues

Preventive maintenance can save you from being stranded. Here are some tips to prevent fuel pump fuse issues on your 1996 Ford Explorer:

Keep the fuel tank above quarter full:

Running the tank low can cause the fuel pump to overheat
The pump uses fuel to cool and lubricate itself
A low tank can cause the pump to draw more current and blow the fuse

Use quality fuel:

Contaminated fuel can damage the fuel pump
Use fuel from reputable stations
Consider using a fuel system cleaner periodically

Check the fuel filter regularly:

A clogged fuel filter can cause the fuel pump to work harder
This increases current draw and can blow the fuse
Replace the fuel filter every 30,000 miles or as recommended

Inspect wiring periodically:

Check the wiring harness near the fuel tank for damage
Look for chafing, corrosion, or exposed wires
Repair any damage immediately

Keep spare fuses in the vehicle:

Carry a variety of fuses, including 20-amp maxi-fuses
This allows you to quickly test and replace a blown fuse

11. KEMSO Fuel Pump: The Best Replacement for Your Ford Explorer

If you have determined that the fuel pump itself is the problem, you need a reliable replacement. The fuel pump is a critical component, and using a low-quality part can lead to repeated failures and more downtime.

Why choose KEMSO Fuel Pumps?

KEMSO offers high-performance fuel pumps that are designed to meet or exceed OEM specifications. When you choose a KEMSO fuel pump for your 1996 Ford Explorer, you get:

OEM Replacement Quality: KEMSO fuel pumps are manufactured to the same specifications as the original equipment. This means a perfect fit and reliable performance, just like the pump that came from the factory.
High Performance: KEMSO fuel pumps are engineered to deliver consistent fuel pressure and flow, ensuring your engine runs smoothly and efficiently. Whether you are driving around town or hauling a load, KEMSO pumps deliver the performance you need.
Lifetime Warranty: KEMSO stands behind its products. Every KEMSO fuel pump comes with a lifetime warranty, giving you peace of mind. If the pump ever fails, KEMSO will replace it at no cost to you.
Affordable Pricing: KEMSO fuel pumps are priced competitively, making them an excellent value. You get premium quality without the premium price tag.
Easy Installation: KEMSO fuel pumps are designed for direct replacement. They come with all necessary components and are easy to install for the DIY mechanic.

Where to buy KEMSO Fuel Pumps:

You can purchase KEMSO fuel pumps directly from the KEMSO website. They offer a wide selection of fuel pumps for various vehicles, including the 1996 Ford Explorer.

Visit the KEMSO website to browse their selection and find the perfect fuel pump for your vehicle:

https://www.kemsoracing.com/

KEMSO is dedicated to providing high-quality fuel system components that keep your vehicle running at its best. With their lifetime warranty and commitment to quality, you can trust KEMSO for all your fuel pump needs.

Final Thoughts

The fuel pump fuse on a 1996 Ford Explorer is a critical component that is easy to check and replace. Always start with the fuse when troubleshooting a no-start condition. Remember that the fuse is a 20-amp maxi-fuse in the Power Distribution Box under the hood. The fuel pump relay is also in the same box, and the inertia switch is in the passenger footwell.

By following the steps in this guide, you can quickly diagnose and fix fuel pump issues without spending money at a repair shop. If you need to replace the fuel pump itself, consider a KEMSO fuel pump for reliable, long-lasting performance.

For more information on fuel pumps and other automotive components, visit https://www.kemsoracing.com/

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