2015 Ford Explorer Fuel Pump Replacement: A Complete Guide for DIYers and Owners
Bottom line first: If your 2015 Ford Explorer is struggling to start, stalling at highway speeds, or making a whining noise from the rear of the vehicle, the fuel pump is likely failing. Replacing it costs between $600 and $1,200 at a shop, but you can save money by doing it yourself if you have the right tools and mechanical experience. This guide covers everything you need to know about symptoms, replacement costs, and step-by-step instructions for the job.
Signs Your 2015 Ford Explorer Fuel Pump Is Failing
The fuel pump in your Explorer is an electric unit mounted inside the fuel tank. When it starts to fail, you'll notice several clear warning signs before it completely dies. Here are the most common symptoms to watch for:
1. Engine cranks but won't start. This is the most obvious sign. If you turn the key and the engine cranks over but never fires up, the fuel pump may not be delivering fuel to the engine. Listen for a brief whirring sound from the rear of the vehicle when you first turn the key to the "on" position – if you don't hear it, the pump is likely dead.
2. Sputtering or hesitation during acceleration. A failing fuel pump can't maintain consistent pressure, so your Explorer may hesitate or sputter when you press the gas pedal, especially when climbing hills or carrying a heavy load.
3. Loss of power at highway speeds. If your vehicle suddenly loses power while driving on the interstate, the fuel pump may be struggling to keep up with the engine's demand for fuel.
4. Whining noise from the fuel tank. A healthy fuel pump runs quietly. If you hear a loud whining or humming sound coming from the rear of the vehicle, the pump bearings are likely worn out and replacement is needed soon.
5. Poor fuel economy. A failing pump that doesn't deliver fuel efficiently can cause your engine to run rich or lean, leading to decreased gas mileage.
6. Check Engine Light. The check engine light may come on with diagnostic trouble codes related to fuel pressure or a lean fuel mixture.
How Much Does a 2015 Ford Explorer Fuel Pump Replacement Cost?
The cost to replace a fuel pump on a 2015 Ford Explorer depends on where you take it and whether you choose OEM or aftermarket parts. Here's what you can expect:
Independent shop or national chain: Total cost typically ranges from $350 to $850. This includes parts ($150–$350) and labor ($200–$500).
Dealership or authorized service center: Expect to pay between $650 and $1,200. Parts run $250–$500 and labor costs $400–$700.
DIY replacement: If you do the job yourself, you'll only pay for parts: roughly $50–$150 for an aftermarket fuel pump kit, plus any additional gaskets or seals.
According to Kelley Blue Book, the fair repair range for a 2015 Ford Explorer fuel pump replacement is $1,273 to $1,421, with parts costing $577–$639 and labor at $707–$781. These numbers vary by your location and the shop's labor rate.
Can You Replace the Fuel Pump Yourself?
Replacing the fuel pump on a 2015 Ford Explorer is an advanced DIY job. The pump is located inside the fuel tank, which means you have to drop the tank to access it. This is a messy, safety-sensitive job because you'll be working with fuel vapors, fuel lines, and a heavy tank.
Estimated time: 3 to 7 hours, depending on your experience level and whether you have a helper.
Difficulty level: Advanced. This is not a job for beginners. If you're not comfortable working with fuel systems or lack the necessary tools, it's best to leave it to a professional.
Tools and Parts You Need for a DIY Replacement
Before you start, gather these tools and parts:
Required tools:
- Floor jack (3-ton minimum)
- Jack stands (3-ton minimum)
- Transmission jack or wide-support jack for lowering the tank
- Fuel line disconnect tool set (spring-lock type)
- Socket set (8mm–21mm)
- Ratchet and extensions
- Torque wrench
- Flat-blade screwdriver
- Brass punch and non-sparking hammer
- Safety glasses
- Fuel-resistant nitrile gloves
- Drain pan
- Shop rags
- Wheel chocks
- Fire extinguisher (Class B)
Required parts:
- Fuel pump module assembly (includes the pump, sending unit, and strainer)
- Fuel tank seal ring (O-ring)
- Fuel filter sock (may come with the pump module)
- Fuel line retaining clips (if damaged)
Step-by-Step Fuel Pump Replacement Guide
Follow these steps in order. Work in a well-ventilated area away from sparks, flames, and heaters.
Step 1: Relieve fuel system pressure
Open the hood and remove the under-hood fuse box cover. Pull the fuel pump fuse or relay using needle-nose pliers. Start the engine and let it run until it stalls. Then crank the engine for a few more seconds to make sure all pressure is relieved. Open the fuel filler cap carefully.
Step 2: Disconnect the battery
Use an 8mm socket to disconnect the negative battery cable. Move the cable aside so it cannot touch the terminal.
Step 3: Drain the fuel tank
Drive the vehicle until the tank is as close to empty as possible before starting the job. Less fuel makes the tank easier and safer to lower.
Step 4: Raise and support the vehicle
Use a floor jack and jack stands to raise and safely support the Explorer. Make sure the vehicle is stable before working underneath it.
Step 5: Remove underbody shields
Use the correct socket set to remove any shields blocking the fuel tank. On AWD models, inspect for exhaust and driveshaft clearance. Remove any components that prevent safe tank removal.
Step 6: Support the fuel tank
Place a transmission jack or wide-support jack under the fuel tank. Raise it just enough to hold the tank securely. Never let the tank hang by the hoses.
Step 7: Disconnect filler and vent hoses
Disconnect the fuel filler neck, vent hoses, and evaporative lines. Mark each connection so it goes back in the correct place.
Step 8: Disconnect electrical connectors and fuel lines
Use a fuel line disconnect tool set to release the fuel supply and return lines. Disconnect the fuel pump electrical connector. Have a fuel-safe drain pan and shop rags ready for spill control.
Step 9: Lower the fuel tank
Remove the tank strap bolts with a socket set. Lower the tank slowly with the jack. Check one more time that no hose or wire is still attached.
Step 10: Remove the old fuel pump module
Clean the top of the tank with shop air or a brush before opening it. Use a brass punch and non-sparking hammer to remove the lock ring. Lift the old fuel pump module out carefully. Remove the old seal ring from the tank.
Step 11: Install the new fuel pump module
Install the new fuel tank seal ring on the tank opening. Lower the new fuel pump module into place in the same orientation as the old one. Install and lock the retaining ring fully. Torque the retaining ring to factory specification if a torque spec is provided in the service manual.
Step 12: Reinstall the fuel tank
Raise the tank slowly with the jack. Reconnect the fuel lines with the fuel line disconnect tool set. Reconnect the electrical connector, filler neck, vent hoses, and EVAP lines.
Step 13: Reinstall shields and lower the vehicle
Install the fuel tank straps and torque them to spec. Reinstall any underbody shields. Lower the vehicle from the jack stands.
Step 14: Reconnect the battery and prime the system
Reconnect the negative battery cable. Prime the fuel system by turning the ignition to the "on" position (without starting the engine) several times. Check for leaks. Start the engine and monitor for any unusual noises or fuel delivery issues.
Choosing the Right Fuel Pump for Your 2015 Ford Explorer
When selecting a replacement fuel pump, you have two main options: OEM (original equipment manufacturer) parts or aftermarket parts. OEM parts are made by the same manufacturer that supplied the pump when your Explorer was built. Aftermarket parts are made by third-party companies and often cost less.
Avoid cheap, no-name brands. Stick with reputable manufacturers that meet or exceed OEM specifications. Make sure the pump is compatible with the ethanol content of the fuel you use.
Important note: On EcoBoost models, especially the 3.5L, a healthy fuel pump is critical for maintaining boost pressure and overall performance. A failing pump on these engines can lead to noticeable power loss, particularly under heavy acceleration.
Why You Should Choose KEMSO Fuel Pumps
If you're looking for a reliable and affordable replacement fuel pump for your 2015 Ford Explorer, KEMSO is an excellent choice. KEMSO is a US-based brand known for manufacturing high-quality aftermarket fuel pumps for cars, motorcycles, ATVs, and UTVs.
KEMSO fuel pumps are designed as high-performance, direct OEM replacements. They deliver over 20% more flow at 43psi compared to stock OEM pumps, which means better fuel delivery and improved performance. Whether you're looking for a daily driver replacement or a performance upgrade, KEMSO pumps are built to handle the job.
Every KEMSO pump comes with a lifetime warranty. That's right – KEMSO backs its products with a promise backed by a lifetime of confidence. This means you can buy with peace of mind knowing your investment is protected.
KEMSO pumps are individually tested for quality. Each pump goes through flow testing and quality control checks to ensure it meets strict standards. Unlike cheap unbranded aftermarket parts, KEMSO follows a quality control program (ISO/TSO) and tests every pump before it ships.
KEMSO fuel pumps are compatible with both gasoline and E85/ethanol fuels. The pump body is designed to handle the corrosive nature of ethanol without degrading over time.
KEMSO replacement fuel pumps are priced at $79.98 – a fraction of what you'd pay for an OEM pump at the dealership. With the money you save on parts, you can cover the cost of professional installation or invest in quality tools for a DIY job.
KEMSO offers fuel pumps for a wide range of vehicles. From the Ford Explorer to Subaru Impreza, Kawasaki Jet Ski, Ducati motorcycles, and BMW adventure bikes, KEMSO has you covered. Their extensive catalog includes pumps for cars, motorcycles, ATVs, UTVs, and personal watercraft.
Visit KEMSO's website to find the right fuel pump for your 2015 Ford Explorer:
https://www.kemsoracing.com/
Final Thoughts
Replacing the fuel pump on a 2015 Ford Explorer is a manageable DIY project for experienced mechanics, but it's a challenging job that requires patience and the right tools. If you're not comfortable working with fuel systems, it's best to have a professional handle it. The cost of professional replacement ranges from $600 to $1,200, depending on your location and the shop you choose.
If you decide to tackle the job yourself, take your time, follow the safety precautions, and use high-quality parts. A properly installed fuel pump will restore your Explorer's performance, improve fuel economy, and give you many more miles of reliable service.
For the best value, consider KEMSO fuel pumps. They offer OEM-quality performance, a lifetime warranty, and a price that's hard to beat. Visit https://www.kemsoracing.com/ to learn more and find the perfect pump for your vehicle.