Ford's Expedition has been the largest SUV in the Ford fleet since the manufacturer ceased production of the Excursion in 2005. The gasoline delivery system on the Expedition, in both the 4.6- and 5.4-liter engines, relies on an in-line fuel filter to trap contaminants before they reach the fuel rail and injectors. Like all filters, the fuel filter has a limit on how much it can trap before it either plugs or passes large amounts of debris -- both outcomes are obviously detrimental to the performance of the Expedition. Ford recommends fuel filter replacement every 15,000 miles to avoid those outcomes.
Start the Expedition. Remove the number nine fuse from the fuse panel which is located under the right side of the dashboard. Wait for the engine to stall out, remove the ignition key and reinstall the fuse. This depressurizes the fuel system.
Open the Expedition's hood. Remove the negative battery cable from the battery using a battery wrench. Shove the cable end down on the side of the battery to prevent it from accidentally contacting the battery terminal.
Climb under the Expedition's driver's side, between the front and rear wheels with the drain pan and fuel line disconnect tool. Look up on the inboard side of the left frame rail to locate the fuel filter. If you can't find it, simply follow the fuel lines from the fuel tank, forward along the frame until you see the filter.
Position the drain pan directly below the old fuel filter. Lift the fuel line retaining clips, located where the fuel lines meet the front and rear of the filter, out of their seats with the fuel line disconnect tool. Be careful with the clips as they break easily and are only replaceable by purchasing an entire new fuel line.
Pull the fuel line off the front and rear of the filter. Pull the old filter out of the retaining band and place it in the drain pan.
Slide the new filter into the retaining band, making sure the flow arrow printed on the side of the filter points toward the engine. Slide the fuel lines onto the front and rear of the new filter. Push the fuel line retaining clips down into place carefully, by hand.
Climb out from under the Expedition with the drain pan and old fuel filter. Wipe any gasoline off your hands with a clean rag. Reconnect the negative battery cable.
Turn the ignition key to the run position (one notch before you start the engine) and count to 10. Shut the key off.
Repeat Step 7 once more to fully prime the fuel system before starting the Expedition.
