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Discussion Starter #1
Hey,

I'm currently trying to fix a friend's 2002 Focus (zetec) with a manufacture date of 27/11/2001. I bought a Delphi pump (not the entire module assembly, part source stated this would work with both the early and late modules), and the strainers do not match. The one in the car is quite large, and sits vertically in the little bucket. The pump won't fit when using the strainer which came with it.

I'm really confused here because I can't find that large vertical strainer anywhere. Even a google image search shows nothing. The old one is filthy, and I'd rather not reuse it. It's like this filter doesn't exist anymore. I've attached pictures of the old strainer, new strainer, and the bucket.

Does the fuel pump itself vary from the early and late design, or is it just the module? What should I do about this pump strainer?

Thanks!
 

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Hey,

I'm currently trying to fix a friend's 2002 Focus (zetec) with a manufacture date of 27/11/2001. I bought a Delphi pump (not the entire module assembly, part source stated this would work with both the early and late modules), and the strainers do not match. The one in the car is quite large, and sits vertically in the little bucket. The pump won't fit when using the strainer which came with it.

I'm really confused here because I can't find that large vertical strainer anywhere. Even a google image search shows nothing. The old one is filthy, and I'd rather not reuse it. It's like this filter doesn't exist anymore. I've attached pictures of the old strainer, new strainer, and the bucket.

Does the fuel pump itself vary from the early and late design, or is it just the module? What should I do about this pump strainer?

Thanks!

So what you were sold was a kit for a module with Metal Rod Supports(Newer style) and you don't have the metal rod supports in your module. The strainer assembly is completely different. Even if you were able so somehow to jam the unit that you have now in the module the improper strainer would cause a fuel leak inside the module and not allow the jet system work properly.

Crummy thing is that no one sell the older style anymore. The only way for you to resolve this situation is to buy a module which is a newer style. Retrofit the tank (per Ford TSB) and install the new module. Retrofit need a special tool which requires some cutting.
 

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Discussion Starter #3
Thanks for the reply! Is it possible to use the new fuel pump with the old strainer in the old module? I could thoroughly clean the strainer, although I know this isn't a great idea. The pumps look similar, although the new pump has a taller outlet.

I also went to a Ford dealership; they only sell the module. But they sell two of them, one before a certain date (which I can't precisely remember) in 2002, and one for after that date. I believe the old one was more expensive. Really not sure how to proceed here.
 

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The dealer has two modules, one with metal support rods and one without...which is basically and older style and new.

You could try fitting the old strainer on there, just make sure it's very snug and has no way of falling off. I have seen shops do this by soaking it in SeaFoam and then blowing it out with compressed air.

Most of the time it's not an option because the strainer is either too dirty to clean or was broken upon removal.
 

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Discussion Starter #6 (Edited)
The old strainer will fit on the new pump, but I have a feeling that the new pump won't fit well in the old style module. I've attached a picture illustrating the difference in height of the pump outputs.

I also found this in another thread, username 'AMC49', which seems to indicate there isn't much point in trying to retrofit an old module with a new style pump:

"I just now changed one finally at around 200K miles, it had been cleaned once around 75K and ran fine until it just quit all at once. The other car still running after years with one cleanout done to it. I put a second design pump w/no module in the early module and can easily say DON'T TRY IT, the differences are many and if you think you are just going to cram it in there you will have a BIG surprise coming if you do. I had to change like 10 different things to do so, although mine runs fine. It is NOT a drop-in, no, no, no, it isn't."

I have a really hard time seeing why no one makes a pump which fits in the old module. I can understand why Ford only sells the new and improved module, but my friend isn't having any of the problems associated with the old modules; his pump is just dead. It's hard to believe I can't find the old pump and strainer as a unit anywhere. It would no doubt be good insurance to replace the whole unit, but that's an awfully big expense.

I'm a little nervous about cutting those tabs off myself (if we go that route), as I obviously don't have the correct tool. Perhaps my local dealership could quickly perform this service, especially if I purchase a $500 module from them.
 

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Discussion Starter #7
More info:

The TSB says the part number for the updated module is 1M5Z-9H307-CA. I called a dealership, and this has been superseded by motorcraft PFS448. Now, I can get a complete gas tank with an updated module (1 year old) in a private sale, but the part number is 1M5U-9H307-CA. The only difference is the fourth character, Z vs. U. I tried to call another dealership (the first guys were closed) and see if this also leads to PFS448, but these guys "don't give out part numbers over the phone." How convenient. Anyway, this seems like it could be a great deal. The tank and fuel pump module are from a 2000 Focus.
 

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Getting an older unit is the best deal in your case. The reason no one makes it is because it was in circulation for such a short period of time. My work specializes in fuel pumps and the older pump is impossible to get by itself. All we can get is the newer style. When shops call us the only option they have is to switch to a newer style module and alter the tank to make it fit. Also when you get that new (used) tank, make sure to clean out the inside as good as possible, minor contamination will kill your pump over a short period of time.
 

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Discussion Starter #9
Good explanation, thanks. Can you or anyone confirm about the parts number issue? From what I've read, that fourth character is just identifying the engineering department responsible for the design. Why there are basically two identical part numbers differing only by engineering number, I'm not sure. For what its worth, Z = Ford Division Service Parts and U = Special Vehicle Operations.
 

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Here I am. I have a new style pump in old style module and can positively tell you they don't fit. I had to do several custom things to make mine work and out of the realm of normal doing that. The new style pump is too tall and too skinny and the top outlet must be shortened or output is blocked off at the top manifold. The top manifold is no longer on center with pump outlet since the top outlet center distance changed too. That twist out of center then lends itself to pump slowly shifting out of place in the bottom cup since not tight there correctly and pump simply falls over sideways to come loose from top manifold. Additionally, pump bottom does not work with the distances involved in the small cup recess in bottom of module. Both th new top and bottom rubbers are incorrect for the old module. The strainer itself is not an issue, I commonly clean them to use over but if you have no workable pump then issue is moot.

You need the later revised pump with spring loaded top and studs. Make it easy on yourself............last July I found a Spectra branded late module for $94 IIRC, I bought the late pump ONLY at $36 and ended up like $60-$65 by the time I completed mods on it to work right. A pain to do, I did it because I like challenge but don't recommend it to others. My other Focus will be getting the late module when that time rolls around.

When Ford did a recall over ethanol clogging the pumps they redesigned them and that redesign happened so early all pump makers dropped the early pump after making a few and went to the later since that is where the sales would be in the future. They saw no sense in making two part numbers that would only get confused by consumers to run their warranty issue out of sight, it is a huge problem already as it is with all the incompetents that cannot change pumps right. They commonly use one gallon of gas to get car up and running, the pumps run dry and tear up in 60 seconds or less like that. Warranty pump coming up! Ford themselves warrantied so many they couldn't count, why they went to another module, to recoup some of that loss. There was really nothing wrong with the early modules at all, I ran mine forever in two Focus cars after simply cleaning the strainers of the early ethanol crud, the industry started filtering the ethanol much better and now hardly any deposit in strainers at all. It was a FUEL problem but bit Ford hard and they decided to bite back with the revised module. We the consumer suffer once again.

I wouldn't worry about that one letter, the '00 tank will work in '02............what the two Focus I have are, I saw no difference in tanks. Modules fit other than that plastic ring which is not that hard to get off. All you are looking for is for pump to sit flat on tank floor. IIRC not all of the ring has to come off to get that, only the slotted areas that the early module snaps into. Maybe the raised ridge, looking at the expensive Ford ring cutting tool and what it would do.
 

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The only 'improved' thing I could possibly see in the new later module would be that if driver strikes bottom of tank on something the pump cannot unsnap from the ring to fall over sideways. Other than that, they moved everything around inside the module but not one bit of that improved the pump to me at all. The newer strainers now filter better but they clog up much easier as a result, maybe that will sell more pumps? I note that most people hold off way too long with early module clogging problems and burn up the pumps as a result, if fixed as soon as the problem begins they can easily go much, much further. Basic human nature being what it is, a better filter that then clogs faster will generate more pump sales. Think about it, that's not as dumb as it sounds.

The older strainers used open pore straining and super easy to clean them and good as new doing so, the later ones are fuzz type to clog easier and impossible to get that microfiltering media truly clean, it will make for more strainer sales and the newer requirements by all pump makers to invalidate warranty if new strainers not bought along with pump are there to reinforce that. The automotive industry is moving toward using every hook and crook they can now to generate multiple parts sales, the more the merrier, single expensive part sales can't pay their bills any longer. I can't wait till I have to buy an entire engine to get a set of spark plugs.......
 

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Discussion Starter #12
Thanks for all the help! Judging by the picture, the fuel tanks do look very similar, but they have different EVAP valves. Actually, I'm not entirely sure what all the hoses are for on top of the tank, but the two tanks have different layouts.

I'm confused as to why all the parts stores need to know if the car was built before a certain date if Ford only makes the one (new and improved) type of module. Checking the motorcraft website, the same module assembly comes up from 2000 to 2004 I believe, and maybe more beyond that. Is there a difference between the 2000, 20001, early 2002 and the newer module if I were to order it at a parts store? The pictures all look the same; they all have metal rods.

Probably going to go with the used 2000 fuel tank/module, take the module out and place it in my existing fuel tank. I'll have to modify the retaining ring, but at least I know the module is only one year old.
 

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Looks like they just condensed to drop a part there, cheaper over 100,000 cars. They do that stuff all the time.

The date tells the part store whether you have the old module or the new, they then can offer the pump by itself if you have the later or the module only if that is the only way you can go there since late pump does not work. Many opt for the pump only with the early car and problems galore there.
 

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Discussion Starter #14
Guys,

Just thought I'd follow up with what I ended up doing. We purchased the fuel tank/1 year old module assembly in a private sale for $150. As previously mentioned, the tanks didn't quite match up (purchased tank was from a 2000) so I couldn't just throw the whole thing back under the car. However, my local Ford dealer was nice enough to cut the tabs on the original tank using the special tool free of charge. After cleaning out all the plastic bits and wiping down the reachable innards of the tank, the module installed quite easily. The car starts easily every time now, has an audible prime at key on, no fuel leaks, no CES lights and a working fuel gauge. Fingers crossed that the module and pump last the remaining life of the car.

Thanks to everyone who provided valuable input, it's much appreciated.
 
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