Ford Windstar Beater - Fuel Pump DIY Hatch

Location of where to cut a hatch to access a 2001 Ford Windstar Fuel Pump. Don't do this unless your vehicle is a beater. Remove fuel tank instead, if you Windstar is in good shape.

[@mitchweber7868]

I just followed this on my Windstar today. Only reason I did it is because I could care less about the carpet and I didn't even remove the carpet, I just cut sections out that will be filled with something else later and covered with something. I think it's worth it because I've seen a lot of guys cut holes in the floor to remove fuel pumps. The only thing I would tell you to watch out for is you're probably going to have to cut a little channel past where you cut the square hole to give the wire harness enough room to wiggle out of there because I knew I didn't want to cut that harness like he did and rewire it. I don't know why, I just don't want to do that lol. So I cut the s*** out of my floor and I cut the s*** out of my carpet because I could care less about this van. I'm just mad that they charged me $10 extra dollars for a total of $25 on Amazon to get the pump here in two days.

[@habibkooljab]

We watched your video and just finished cutting the hole to remove the fuel pump, great video thank you so much!!

[@monotheis6889]

After watching the video, and reading the comments, I'm just going to cut out a much larger section to have total access to everything below. Some hinges, a gasket and some flanges welded in will work nicely. I have a 2000, AND 2002 Windstars. Thank you for finding out where to start, tho. I looked underneath at the tank and almost torched the whole van just to be done with it... 😂

[@iceyu2235]

This is exactly the alternative I was looking for! My car's rusty straps and bolts really appreciate being left alone! Thank you!

[@michaelbruns473]

Thanx! Your hack works perfecly ! Saved a lot of work.

[@chrishampton5915]

Thanks brother, I was just figuring out that there wasn't a access panel to get to it. Right on man and thank you

[@Quickened1]

right on man, you saves by the day for me! My fuel pump went out at a jobsite and I had no other way home. Having replaced a few, in the tank pumps over the years, I can tell you I was in no mood for dropping the tank in my 2000 windstar, maybe it has something to do with me dropping a kidney stone right now! I just wanted to say thanks, as you did the most difficult part, which was actually locating it! I have to admit, I had to look at the vid about 20 times, because I couldn't tell if the hole was between the forward most set of seat anchors, or the second set. After looking really close, I could tell it was the second set and I went to chopping! I didn't measure, I just eyeballed it and got it perfectly cut the first try. and I actually stayed behind the little crossmember and the hole is pretty much a perfect 7 inch square. I was able to pull my pump and remove the motor, then I reversed polarity several times on it and it got me home!!!! Now, when I get the new motor, it'll take me 15 minutes to get it in! Not four hours of rolling around on the ground, knuckle busting and cursing, along with a crick in my kneck! Thanks Man! 👍

[@watcherwatchmen7785]

I used the same technique that you did on a 2000 ford windstar and was able to eyeball the correct location to cut, thanks to your video. The only difference is that I drilled and mounted hinges with rivets. Since it's covered with carpet and not in an area where anyone would be walking this works perfect. I'm not worried about the new fuel pump going out anymore. Thanks for using your van and taking the time to make this video.

[@DavidBarkes]

WOW. Delighted I could make a difference for someone. So glad it worked out for you. Great idea about the hinges! Thanks for the comment.

[@batboy020876]

Good work on locating it but there's no need to measure there anything else from now on it's only look at the grooves in the plate metal on the floor and anybody can find it now I use the same thing on 2002 work great thank you so much for your help awesome video man you save me a bunch of work but this technique is far easier than dropping the tank don't ever drop the tank

[@AD0321]

Outstanding Thank you : I have a 1998 Ford Windstar I used the measurements and Bingo the fuel pump was right there under the plate I just cut out. Thank you for the video it works with a 1998 ford Windstar.... NICE....

[@DavidBarkes]

Awesome! Glad it worked well for you :-)

[@quevicular]

I Like it a loooooot. Tired of getting under vehicles to work on them My 2000 rear REM pooched because the thing got soaked and fried out because the rear window leaks down on top of it, so if you guys have problems with a variety of blown fuses happening, well this thing dead shorts and causes all sorts of problems. Vehicle will crank but wont start and various crap on the dash wont light up and no door locks and and and.

[@jewelm3960]

You did WAY more work than it would take to drop the tank! Not to mention cutting a hole in your floor for something you'll probably never need to replace again! What a waste of time and effort!

[@nicolasjax8684]

i dont mean to be off topic but does any of you know a method to log back into an Instagram account? I was dumb forgot my password. I would appreciate any assistance you can give me.

[@thomaskyler8837]

@Nicolas Jax Instablaster :)

[@nicolasjax8684]

@Thomas Kyler Thanks for your reply. I got to the site on google and im trying it out now. I see it takes quite some time so I will reply here later when my account password hopefully is recovered.

[@nicolasjax8684]

@Thomas Kyler it did the trick and I actually got access to my account again. Im so happy:D Thank you so much you saved my account!

[@thomaskyler8837]

@Nicolas Jax glad I could help :D

[@mike7044863]

Ive dropped the tank in the middle of winter out in the street soak and wet and cold .......Its not that much to do if you have an almost empty tank its much easier . . Also , drop tank from passenger side leaving filler tube connected and you still have room to get in there and do the job .

[@naelair]

Thank you.

[@owensrayfeilds6800]

forgot to put video high up to seee the door n rear tires,,,but thankyou,,i was about to cut also,,but did not know where to cut,,nice,,,already did a car,,not easy,,on the windstar,,,

[@jeremyp5027]

whoooa looks like it was just more easy to drop the tank, unless its full.

[@Dot_Compositions]

I was so close to doing this - bought a used 2001 - stutters a bit when simi low on fuel.. long story short.. I dropped the fuel tank only to find a hole where there previous owner did this exact thing. lmao

[@DavidBarkes]

LMAO!!!!

[@quevicular]

I wouldnt weld too much, you may catch on fire. Maybe spot it in a few places then spooge on some slicko flex

[@wandaarnold2796]

I would rather drop the tank, too much extra work and it's kinda dangerous to use a welder around a gas tank

[@Quickened1]

Wanda Arnold no welding needed! Consider this, if you buy a generic fuel pump, it's likely you will be replacing it again in the future. I just performed this procedure, and now, I can change the fuel pump almost as quick as a tire!!! How many times are you gonna drop that tank b4 this makes sense to you? BTW... if you cut really nice, you'll only have a 7" square hole. Now bond pieces of plastic to the edge of the plate you removed, with about a1/2" overhang, and then bond it in place using something like silicone or one of the industrial grade bonding agents. Personally, I'll just use silicone so its not too difficult to remove it in the future... Seals it and bonds it....Walla!

[@rogeranderson5092]

I would never recommend cutting a hole in floor to replace a fuel pump. Why it's not a good ideal ? 1 reason is if your not extremely careful you can cause damage possibly to any electrical wires. & fuel lines & and depending on how they run the rear brakes you could damage the lines or possibly cut straight threw one of the lines. And last but not least if the hole is not sealed up completely you could get carbon monoxide poisoning . Always drop the tank. it's not worth you getting seriously hurt just to save a little time

[@kennethconnerjr5510]

Hmmm... maybe 7"....maybe 2 ".... guess he never heard of a measuring tape.

[@rrich52806]

Wow. I miss my 74 Fiat Spider. the electric fuel pump was in the trunk in the spare tire well..

[@CurlyQLink]

I have the exact same 2001 Windstar SEL. (P.O.S.). I bought this vehicle brand new and it has been, hands-down, the WORST vehicle (34 total) that I have owned. I will NEVER EVER buy another FORD. They are $HIT.

[@ryanrobs227]

I wish you hadnt guessed at the measurments. Im certain it wouldnt have been too hard to find a tapemeasure.

[@PCDEC]

Just cut where he did. The floor in your van will have the same grooves and such so it's simple to just freeze the video at say 2:33 and just use it as a reference.

[@habibkooljab]

We just cut ours using this video as a guide, it worked great.

[@heavymechanic2]

The floor pan was sealed for a reason, it keeps fuel vapors out of the car. Some imports have a cover that has a tar seal. This is just bad advice.

[@jesseschmidt04]

Shut up limp wrist

[@harryw3910]

Hello using you idea but having a hard time locating where to cut

[@lisaperry8919]

I dropped the tank and I need to know how to get the new fuel pump back int the assimbley

[@dennisbaut887]

David..i have a 1998 windstar with what i think is an intermittent fuel pump problem. Sometime the car will not start unless i cycle the ignition on and off a couple of times. Then it runs great..high speed, pass gear..no hickups. Fuel filter ok. Not a spark problem or injector problem. Before i cut a hole...where is the fuel pump relay located so i can check that? When i turn the key on but before the starter i can hear the hum from the pump. It starts then quits in about 3 seconds. Coming up to pressure. Appreciate any words of wisdom..thanks

[@DavidBarkes]

Hello Dennis. I am sorry that I do not know the location of the relay and I no longer have the old windstar. Nor am I a mechanic. I do think that you are correct trying to find something other than the fuel pump however. If the pump itself runs and comes up to pressure sometimes, I think that the problem may lie elsewhere. Sorry I do not have a better answer for you. good Luck.

[@dennisbaut887]

@@DavidBarkes thank you..i'll keep you in the loop

[@FishOnIsMyHandle]

@@dennisbaut887 Hi Dennis - what resolved it? Ours is doing the exact same thing, Thanks for any help !

[@kervinrodriguez1301]

Wanna get a measuring tape instead of guessing

[@jmitch6764]

Good for you. I hope you have learned to stay away from Ford Windstars . I could share many lessons.

[@autisticpressurewasher7404]

Is it the same for a 1996

[@alstevens44]

Is this the same as 2003 windstar, it's good idea thanks

[@DavidBarkes]

Sorry I do not know. Perhaps try Google for which years are the same.

[@DavidBarkes]

This video seems to suggest that 2001 - 2003 are the same: kzbin.info/www/bejne/kJ3GdGyImNh4ha8

[@harryw3910]

Which well back seat?

[@DavidBarkes]

Hello. I think if you use the raised rib pattern and the black cable wire guide you should be able to locate were this is in the vehicle if you remove the carpet. It is the forward seat I believe, It was a long time ago,

[@ducks_love_bread]

Is this the same on a 98?

[@DavidBarkes]

Sorry I do not know anything about other years. Perhaps someone else will comment.

[@Quickened1]

right on man, you saved the day for me! My fuel pump went out at a jobsite and I had no other way home. Having replaced a few, in the tank pumps over the years, I can tell you I was in no mood for dropping the tank in my 2000 windstar, maybe it has something to do with me dropping a kidney stone right now! I just wanted to say thanks, as you did the most difficult part, which was actually locating it! I have to admit, I had to look at the vid about 20 times, because I couldn't tell if the hole was between the forward most set of seat anchors, or the second set. After looking really close, I could tell it was the second set and I went to chopping! I didn't measure, I just eyeballed it and got it perfectly cut the first try. and I actually stayed behind the little crossmember and the hole is pretty much a perfect 7 inch square. I was able to pull my pump and remove the motor, then I reversed polarity several times on it and it got me home!!!! Now, when I get the new motor, it'll take me 15 minutes to get it in! Not four hours of rolling around on the ground, knuckle busting and cursing, along with a crick in my kneck! Thanks Man! 👍