2006 Ford Explorer Fuel Pump Location: Where to Find It and How to Access It

If you own a 2006 Ford Explorer and suspect a fuel delivery problem, the fuel pump itself is located inside the fuel tank, which sits beneath the rear of the vehicle. Unlike some older trucks that offered access panels under the rear seat, the 2006 Explorer requires lowering the fuel tank to reach the pump assembly—there is no shortcut access door from inside the cabin . Before you drop the tank, however, you should know that many fuel-related no-start and stalling issues on this generation are actually caused by a separate component called the Fuel Pump Driver Module (FPDM), not the pump itself . This guide walks you through the exact location of both parts, how to tell which one is failing, and what the replacement process involves.

1. The Fuel Pump Location: Inside the Fuel Tank

On the 2006 Ford Explorer, the electric fuel pump is mounted inside the fuel tank as part of a single assembly that also includes the fuel level sending unit and the strainer (sock filter) . The fuel tank is positioned under the rear cargo area, between the rear axle and the rear bumper. There is no access panel under the rear seat or in the cargo floor that would let you reach the pump without dropping the tank . This design applies to all 2006 Explorer body styles, including the SUV and the Explorer Sport Trac pickup variant.

To access the pump, you must:

  1. Disconnect the battery to eliminate any risk of sparks or fire.
  2. Depressurize the fuel system by removing the fuel pump relay or fuse and cranking the engine briefly until it stalls.
  3. Siphon or drain as much fuel as possible from the tank to reduce its weight .
  4. Disconnect the filler neck hose and the EVAP (evaporative emissions) lines connected to the tank.
  5. Support the tank with a floor jack and a wide board to distribute the weight.
  6. Remove the tank straps (two metal straps) and carefully lower the tank a few inches .
  7. Disconnect the electrical connector and fuel lines from the top of the pump module, then remove the locking ring to lift the pump assembly out.

On some 2006 models, you may also need to remove the driveshaft for clearance, depending on the drivetrain configuration . The job is rated roughly 4 out of 5 on a difficulty scale—doable for an experienced DIYer, but time-consuming and physically demanding .

The factory replacement part for the 2006 Explorer fuel pump assembly is the 6L2Z-9H307-A, which lists for around $367 and sells for roughly $228 at discount OEM parts retailers . This assembly includes the pump motor, the fuel gauge sending unit, and the strainer. The same assembly is used on the 2006 Mercury Mountaineer, and the Explorer Sport Trac uses a similar unit .

2. The FPDM Location: Behind the Rear Trim Panel

The Fuel Pump Driver Module (FPDM) is a small electronic box that controls the voltage delivered to the fuel pump motor. It uses Pulse Width Modulation (PWM) signals from the Powertrain Control Module (PCM) to run the pump at the correct speed for the engine's demand . It is a separate component from the fuel pump itself, and it fails far more often on 2004–2010 Explorers .

On the 2006 Ford Explorer SUV, the FPDM is located inside the cargo area, behind the interior trim panel on the passenger-side rear quarter panel, just forward of the taillight assembly . To access it:

  1. Open the rear liftgate.
  2. Fold down the second- and third-row seats to create working room.
  3. Remove the plastic trim along the rear cargo floor and around the right rear panel. A trim tool or flathead screwdriver works best for popping the clips without breaking them .
  4. The FPDM is a small silver or black metal box mounted to the sheet metal. Disconnect the electrical connector, remove the mounting bolts, and pull it out.

On the Explorer Sport Trac (the pickup version), the FPDM is mounted under the vehicle, on the passenger side, near the front edge of the fuel tank . It is bolted to the underside of the body or the frame rail, fully exposed to road debris, moisture, and salt. This exposed location is why the module fails so often on Sport Trac models—corrosion builds up quickly .

3. Why the FPDM Fails and How to Spot It

The original FPDM on these vehicles has a known design flaw: it is mounted in a die-cast housing that is prone to corrosion, and it sits directly against the steel frame . Over time, galvanic corrosion (caused by dissimilar metals touching) eats into the module, and road debris accumulates underneath it, trapping moisture . The result is intermittent or complete loss of fuel pump power.

Common symptoms of a failing FPDM on a 2006 Explorer include:

  • Engine cranks but will not start—you hear the starter turning but the engine never fires.
  • Sudden stalling while driving—the engine dies with no warning, and may or may not restart after cooling down .
  • Intermittent no-start conditions—the car starts fine some days, then refuses to start others.
  • Low fuel pressure readings during diagnosis, even though the pump itself is working .

A failing FPDM can mimic the symptoms of a bad fuel pump, so it is critical to test the module before dropping the fuel tank . If you replace the pump but the FPDM is the real culprit, you will still have the same problem. The reverse is also true—a weak pump can mimic a bad FPDM.

The good news is that the FPDM does not require programming. It is a plug-and-play replacement. You can swap in a new or used unit without any dealer-level software or coding .

4. Testing the FPDM Before You Replace Anything

You can test the FPDM with a digital multimeter in about 30 minutes. The module has a 4-pin electrical connector with male spade terminals . The four circuits are:

  1. VPWR (12V power input)—this should show battery voltage with the key on.
  2. PWR GND (power ground)—this should show continuity to chassis ground.
  3. FPC (Fuel Pump Control)—this is the PWM signal from the PCM. It should show a varying voltage or a square wave pattern when the engine is cranking.
  4. FPM (Fuel Pump Monitor)—this is a feedback signal that confirms the pump is running. It should show activity when the pump is commanded on .

If you have 12V power and ground at the module but no FPC signal, the problem is upstream (PCM, wiring, or a safety switch). If you have signal but the pump does not run, the FPDM is likely bad. If the FPDM tests fine but the pump still does not run, check the pump itself .

Important safety note: Do not drive the vehicle if the FPDM is failing. The engine can stall at any time, including at highway speeds, which creates a serious safety risk .

5. Replacement Cost and Labor Estimates

Because the fuel pump is inside the tank, replacement labor is significant. For a 2006 Ford Explorer, the estimated total cost for a fuel pump replacement ranges from $1,233 to $1,503, including parts and labor . The fuel pump assembly itself (OEM) costs roughly $228 to $375 at discount dealers . Independent shops typically charge $330 to $485 for labor , while dealerships charge more.

The FPDM replacement is far cheaper. The OEM module for the 2006 Explorer (part number 6L2Z-9D372-A) lists for about $229 and sells for roughly $117 . Dorman's aftermarket version (part number 590-001) is a direct OE FIX replacement and typically costs $40 to $70 depending on the retailer . Labor for FPDM replacement is minimal—about 1 to 1.5 hours .

If you are paying a mechanic, always ask them to test the FPDM first before recommending a fuel pump replacement. A shop that jumps straight to "you need a new fuel pump" without checking the module is either poorly trained or looking to pad the bill.

6. The 2009 Parts Change You Need to Know

There is an important production change that affects 2006 Explorer owners down the road. For vehicles built after January 20, 2009, the fuel pump assembly is physically different from the one used in earlier models . The electrical connectors, fuel line connections, and the housing itself differ. If you are buying a replacement pump, you must verify the build date of your vehicle or the part will not fit correctly .

For a 2006 model year vehicle, this change is mostly irrelevant unless you are buying a used pump from a 2009 or 2010 donor vehicle. Always confirm the part number matches your 2006 application before purchasing.

7. Step-by-Step: Removing the Fuel Pump on a 2006 Explorer

If you have confirmed the pump itself is bad (not the FPDM), here is the full procedure:

Tools you will need:

  • Floor jack and jack stands
  • Wide board or plywood for tank support
  • Socket set and ratchet
  • Flathead screwdriver or trim tool
  • Fuel line disconnect tool (plastic quick-disconnect)
  • Drain pan and siphon pump
  • Safety glasses and gloves

Step 1: Disconnect the negative battery cable. Work in a well-ventilated area.

Step 2: Remove the fuel pump relay from the under-hood fuse box. Crank the engine for 5–10 seconds to relieve fuel pressure. The engine may start briefly, then stall as the fuel in the lines runs out.

Step 3: Raise the rear of the vehicle securely on jack stands. The fuel tank is between the rear axle and bumper.

Step 4: Siphon as much fuel as possible through the filler neck. A full tank of gas is too heavy and dangerous to lower.

Step 5: Disconnect the fuel filler hose from the tank. On the 2006 Explorer, this is a large rubber hose with a clamp. Also disconnect the small EVAP vent hose.

Step 6: Place the floor jack under the tank with the plywood board on top. Raise the jack just enough to take the weight of the tank.

Step 7: Remove the two tank straps. On some models, you may need to remove the skid plate first .

Step 8: Lower the tank slowly. You only need to lower it a few inches to access the top of the pump module. Keep the tank supported—do not let it hang by the hoses.

Step 9: Disconnect the electrical connector from the top of the pump module. Disconnect the fuel lines using the quick-disconnect tool.

Step 10: Remove the large locking ring (retainer ring) using a hammer and a flat punch, or a special fuel pump lock ring tool. Turn it counterclockwise.

Step 11: Lift the pump assembly straight out of the tank. Note the orientation of the float arm so the new pump sits the same way.

Step 12: Install the new pump assembly, replace the O-ring seal on the tank opening, and reinstall the locking ring. Reconnect all hoses and the electrical connector.

Step 13: Raise the tank back into position, reinstall the straps, and reconnect the filler hose and EVAP lines.

Step 14: Reconnect the battery, install the fuel pump relay, and turn the key to the ON position for 2 seconds, then OFF, then ON again—repeat three times to prime the system before cranking.

Step 15: Check for fuel leaks before starting the engine .

8. Should You Replace Just the Pump or the Whole Assembly?

It is possible to buy just the internal pump motor, but it is not recommended . The complete module includes the fuel level sending unit, the strainer, and the housing. These components wear out at different rates. If you replace only the motor, you may soon face a bad sending unit (inaccurate fuel gauge) or a clogged strainer. Replacing the entire assembly costs more but results in a more reliable repair .

Also consider replacing the in-line fuel filter at the same time. A clogged filter puts extra strain on the new pump and is a leading cause of premature pump failure .

9. KEMSO Fuel Pump: A High-Performance, Lifetime Warranty Option

When the time comes to replace the fuel pump on your 2006 Ford Explorer, consider KEMSO as your parts source. KEMSO fuel pumps are built to high-performance standards and serve as direct OEM replacements for a wide range of vehicles, including Ford, Lincoln, Mazda, and Mercury models. Each pump is designed to match the fit and function of the original factory part, so installation is straightforward and no modifications are needed. KEMSO backs every fuel pump with a lifetime warranty, giving you peace of mind that goes far beyond what most aftermarket brands offer. Whether you are restoring a daily driver or upgrading a weekend project, KEMSO delivers dependable fuel delivery at a competitive price. Visit https://www.kemsoracing.com/ to browse their full catalog of fuel pumps and see which one fits your Explorer.

10. The Bottom Line

The fuel pump on a 2006 Ford Explorer lives inside the fuel tank, under the rear of the vehicle, and there is no shortcut to reach it—you must lower the tank . The Fuel Pump Driver Module, which controls the pump, lives behind the passenger-side rear trim panel inside the cargo area on the SUV, or under the vehicle near the fuel tank on the Sport Trac . Because FPDM failure is so common on these vehicles, always test the module first before spending time and money on a fuel pump replacement . If the pump is confirmed bad, budget between $1,200 and $1,500 for a professional replacement , or tackle the job yourself with basic hand tools and a floor jack. And when you buy a replacement pump, choose a brand you can trust—KEMSO offers high-performance, OEM-replacement fuel pumps with a lifetime warranty. Check out their selection at https://www.kemsoracing.com/ before you order.


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