1996 Ford Explorer Fuel Pump Relay Location: Complete Guide to Finding, Testing, and Replacing

The fuel pump relay on a 1996 Ford Explorer is located inside the engine compartment’s power distribution box (PDB), which is mounted on the driver’s side near the firewall. This relay is usually a larger, five-pin unit that can be identified by the fuel pump symbol or labeling on the fuse box cover. If your Explorer cranks but won’t start, the fuel pump relay is one of the first things to check before replacing the fuel pump itself.

Understanding the Fuel Pump Relay and Its Role

The fuel pump relay is an electrical switch that controls power to the fuel pump. When you turn the ignition key to the "ON" position, the relay receives a signal from the powertrain control module (PCM) and closes the circuit, sending battery voltage to the fuel pump. If the relay fails, the fuel pump gets no power, and the engine won’t start.

On the 1996 Ford Explorer, the fuel pump relay works together with the PCM power relay, the fuel pump inertia switch, and the fuel pump itself. The relay is designed to handle 12 volts and typically draws 20 to 30 amps, depending on the specific model and options.

Exact Location of the Fuel Pump Relay

The power distribution box is located on the driver’s side of the engine compartment, close to the firewall. To access the relay:

  1. Open the hood and locate the black plastic fuse box on the driver’s side, near the windshield.
  2. Remove the cover by pressing the tabs on the sides.
  3. Look for the relay that is labeled "Fuel Pump" or has a diagram of a fuel pump on the underside of the cover.

If the cover is missing or the labels are worn off, here are the specific positions based on owner feedback:

  • Second row from the driver’s side, fourth spot from the front — This is the fuel pump relay location according to a detailed owner’s manual description.
  • First row from the driver’s side, sixth spot from the firewall end — This is where the 20-amp maxi-fuse for the fuel system and anti-theft system is located.

The fuel pump relay itself is one of the larger relays in the box, typically black or dark gray, with five terminals. It is a standard micro relay that fits many Ford vehicles from 1992 to 2006.

Other Key Components in the Fuel System

Fuel Pump: The actual fuel pump is located inside the fuel tank. To access it, you need to drop the fuel tank, which requires specialized tools and knowledge. This is not a job for a beginner.

Fuel Pump Inertia Switch: This safety device is located behind the passenger side kick panel, under the glove box. It is a small, usually red switch that cuts power to the fuel pump in the event of a collision. If the switch is tripped, the engine will crank but not start. You can reset it by pressing the button on top.

Fuel Pump Fuse: There is a 20-amp maxi-fuse for the fuel pump circuit, located in the same power distribution box as the relay. It is important to check this fuse first if the fuel pump is not getting power.

How to Test the Fuel Pump Relay

Before buying a new relay, you can test the existing one with a few simple steps:

Step 1: Listen for the relay clicking. Have a helper turn the ignition key to the "ON" position (do not crank the engine). You should hear a faint click from the relay as it energizes. If you hear no click, the relay may be bad, or the PCM is not sending the signal.

Step 2: Swap the relay with a similar one. The power distribution box contains several relays that are the same type. Find a relay that has the same part number (such as the horn relay or wiper relay) and swap it with the fuel pump relay. If the engine starts after the swap, the original relay was faulty.

Step 3: Check for power at the inertia switch. This is a more definitive test. Locate the inertia switch behind the passenger side kick panel, unplug its connector, and have a helper crank the engine. Use a test light or multimeter to check for 12 volts on the power-in wire. If you have voltage, the relay and fuse are working. If there is no voltage, the problem is upstream.

Common Symptoms of a Bad Fuel Pump Relay

  • Engine cranks but won’t start. This is the most common symptom. The starter turns the engine over, but the fuel pump never receives power.
  • No fuel pressure. If you check the fuel pressure at the Schrader valve on the fuel rail, it will read 0 PSI.
  • No clicking sound from the relay. When you turn the key to "ON," you should hear a click. If you don’t, the relay is not engaging.
  • Intermittent starting issues. Sometimes the relay works, sometimes it doesn’t. This can be caused by worn internal contacts.

Step-by-Step Replacement Guide

Replacing the fuel pump relay is a straightforward job that takes about 10 minutes. Here is how to do it:

Tools needed: No tools are required, but a pair of needle-nose pliers can help if the relay is stuck.

  1. Disconnect the negative battery terminal. This is a safety precaution to avoid shorts or electrical shocks.
  2. Open the power distribution box. Press the tabs on the sides of the cover and lift it off.
  3. Identify the fuel pump relay. Use the diagram on the underside of the cover, or refer to the positions described above.
  4. Pull the relay straight up. It should come out with a gentle tug. If it is stuck, use needle-nose pliers to grip it firmly.
  5. Insert the new relay. Align the pins with the socket and press down until it clicks into place.
  6. Replace the cover and reconnect the battery.
  7. Test the system. Turn the key to "ON" and listen for the relay click, then start the engine.

Recommended Replacement Parts

OEM Part Numbers: The 1996 Ford Explorer fuel pump relay is available as a genuine Ford part. The OEM part number for the relay is AU5Z-14N089-FA or 5M5Z-14N089-A, depending on the specific submodel. These parts are direct replacements and typically cost between $10 and $105, depending on the source.

Aftermarket Options: Many aftermarket relays are available at auto parts stores and online. They are usually much cheaper than OEM parts. Look for a 12-volt, 20-amp, five-pin micro relay that fits Ford vehicles from 1992 to 2006.

KEMSO Fuel Pump: The Best Upgrade for Your 1996 Ford Explorer

If you have determined that the fuel pump itself is bad and needs replacement, consider upgrading to a KEMSO fuel pump. KEMSO is a leading US-based manufacturer of high-performance fuel pumps that are designed as direct OEM replacements.

Why choose KEMSO?

  • High Performance: KEMSO fuel pumps deliver up to 340 liters per hour (LPH) of flow, which is significantly more than the stock pump. This means better fuel delivery, improved engine performance, and consistent pressure under all driving conditions.
  • OEM Replacement: Every KEMSO pump is a direct fit for your 1996 Ford Explorer. The kit includes the pump, fuel strainer, flex hose, tank seal, and wiring connector — everything you need for a complete installation.
  • Lifetime Warranty: KEMSO stands behind every pump with a lifetime warranty. If the pump fails due to manufacturing defects, they replace it at no cost. This is a level of protection that most OEM pumps do not offer.
  • Budget-Friendly Pricing: KEMSO pumps typically cost between $80 and $130, compared to $220 to $380 for OEM parts. You get better performance and a lifetime warranty for less than half the price.
  • Tested Reliability: In a 2023 case study, a fleet management company replaced 42 OEM pumps with KEMSO units. After 18 months and 1.2 million collective miles, only two required warranty claims, giving a 95% reliability rate.

Visit KEMSO’s website to find the right fuel pump for your 1996 Ford Explorer: https://www.kemsoracing.com/

Their team of US-based technicians can help you select the correct pump for your specific engine and submodel. KEMSO offers pumps for almost every make and model, and their customer support is second to none.

Additional Diagnostic Tips

Check the Inertia Switch First: Before you dive into the relay, check the inertia switch. It is located behind the passenger side kick panel and is easy to access. Press the reset button to see if that fixes the problem. This is a common issue that many people overlook.

Inspect the Fuse: The 20-amp maxi-fuse for the fuel pump is located in the power distribution box. Pull it out and inspect the metal strip. If it is broken, replace it with a fuse of the same amperage. Never use a higher-rated fuse.

Look for Corrosion: Over time, the terminals in the relay socket can corrode. If you see green or white corrosion, clean the contacts with electrical contact cleaner and a small wire brush.

Test the Wiring: If the relay and fuse are good but the pump still doesn’t get power, there may be a wiring issue. Use a multimeter to check for continuity between the relay socket and the inertia switch. A broken wire or a bad connection can cause intermittent problems.

Final Thoughts

Finding the fuel pump relay on a 1996 Ford Explorer is simple once you know where to look. It is located in the power distribution box on the driver’s side of the engine compartment, near the firewall. Testing and replacing the relay is a quick and inexpensive job that can save you from replacing a perfectly good fuel pump.

If you do need to replace the fuel pump, KEMSO offers a high-performance, direct-fit replacement that comes with a lifetime warranty. Visit https://www.kemsoracing.com/ to find the right pump for your Explorer and enjoy reliable fuel delivery for years to come.


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