My 05 pump motor went out AND the hose that's part of the assembly split in the tank. Double whammy.

New pump assy from Rockauto, and she fired right up.

EDIT: Nope... got it from Amazon:

 

Yes it does. Upstream from the lines things are different (in two different ways depending on year) but as far as I know the "last mile" is the same. On my '10 they were replaced at approx. 40k miles in 2017. "New" lines working fine and looking good so far.

Hybrids differ here: A 2006 has the hydraulic pump ABS brake system, not the vacuum-assist with little independent electric vacuum pump that supplies "suck" when the the car is in EV mode. Exercise caution. Remember that the system pressurizes the brakes according to its own schedule even when the engine is OFF and you are asleep in your bed, and requires a different bleeding procedure. You can turn off the automatic pressurization through a series of actions involving the pedal and other controls that I don't remember, or just disconnect the 12V battery, but after it's back together and running you will need to bleed it also.

 

FINALLY got a chance to work on the vehicle again, seems that I only get freed up on Tuesday afternoons... . Anyway, like I suspected, the brake hose was the defective type, and snapped at the fitting, just like they do. Quick replacement, followed the Ford procedure to pull battery and fuses, then bled the brakes. Fortunately, the other side had the newer hose so I didn't have to replace it.

When I was working on it last week, I THOUGHT that I had ordered a new fuel pump from Rock Auto, and I was expecting it to be delivered today. It didn't show up. I discovered that for some reason, my order didn't complete, and I never checked for a verification email.

Oh well, just need to decide whether to use some Ford parts I have lying around to manually rebuild the pump, or just order a new one and wait a week.

 

Strange with the Rock Auto order, usually their website works great. But sometimes you miss a step. Chalk it up to cosmic rays. It was definitely cosmic rays. Lol.

Glad to hear about the brake line and bleeding. It sounds like you're a noncomplaining type who knows what they're doing. What did you do for the bleeding proc.?

Let us know what you decide on the pump, take a pic or two! If you decide to rebuild it yourself, it'll be cool "hacker" documentation (in the good sense of the term, like it should be.)

 

Finally figured out that I loaded my cart, filled in the required info, then didn't click send.

Been really busy lately, figured the transition to being semi-retired would mean more free time...not just yet. Been even more busy that usual doing IT work for one of the clients I kept, and working on my rental property.

Noncomplaining...probably. I've been working on cars since I was a teenager, always enjoyed it, but work and family have kept that to a minimum for a number of years. Looking at this hybrid as a fun challenge, it allows me to learn some new stuff and indulge my love of wrenching.

After this housing mess dies down, I'm going to buy/build a bigger garage with a house attached. At the moment I have a oversized suburban house with a dinky 2 car garage, and no room to add additional space. I want at least a 3-4 space garage with a lift.

I cross referenced the fuel pump assembly, and unfortunately, it looks like the assembly itself is unique to 2005-07 Hybrids, not even the Gas 4cyls are compatible. I do have a couple of new bare Ford pump motors lying around, and a pump assembly from a 202 Escape v6, so if I get some time over the weekend, I might tear apart the pump assembly and see if they fit.

 

Yeah the proper space and place to work is really super important. I don't even have a garage! so all my stuff is on my back outside or I pay someone who has a garage to borrow it for a while. I've been lucky that so far I haven't needed to do much serious work on this car, and the things I have done were either simple to accomplish or things that I let my "trusted wrench" perform for me. On the other hand, for a variety of reasons that I won't go into I have found myself with extra time in front of the computer, so I've probably spent too much time "contributing" here, boring everyone to death. I thank people for their forbearance of that, it's really because I love the car and I want to see people who have them achieve good outcomes. They're somehow more than the sum of their parts, what can I say?

I think these cars are excellent choices for someone like yourself, who can spend the needed time to do the work correctly and keep them running. The parts are available and the manuals and good will and cameraderie exists, esp. on this forum. I think the FEH forum is *always* being viewed by at least 20 guests and sometimes as many as 100 or more. It far outstrips many of the others here at EVF, which says something for a car that was last made in 2012.

Good luck and have fun!

 

In a few months I might have a garage but currently I am doing everything on the floor in a parking space. I did a transmission (at least it was RWD) on the floor before too. If you have parts, rebuild the pump. They like to sell the whole thing as a "housing" but really there are just cheap individual parts inside and most of them come apart. $100 fuel pump vs $300 fuel pump and all.

 

Reminds me of when I was growing up, my parents didn't have a garage..or a driveway. I can remember changing out an automatic transmission on the street in front of our house. Not fun, but definitely a learning experience. When I was looking for my first house, I was still young and single and figured when I got married in a few years, I would have to buy a different house anyway, so I had two criteria of my own: close to work, and with a two car garage. Fortunately, I was able to find a ranch house in a suitable location where the previous owner had added an OVERSIZED two car garage with it's own heating unit!

My friends and I did a lot of projects in that garage, but as expected, when I settled down and started a family, I ended up with a fancy suburban house, with a two car garage that can BARELY fit two cars.

But enough reminiscing, as you said, the people here are fantastic, and there's a lot of good information here. I got the full set of Ford manuals off of eBay dirt cheap, I already had ForScan, and when I get this working for wages thing tamed down a bit, I'm going to get the beast running!

Take care.

 

Oh well, another Tuesday, and I'm working on the Hybrid again. Yes, it's weird that I only end up doing this on Tuesday afternoons, but my schedule is kinda wonky lately.
Got the old pump out and tore it apart, pretty easy to disassemble, just need a REALLY small nut driver - 3/16".


Pretty gunky inside, the pickup filter was uglier than it looks

Standard size and length for Ford pumps

The pumps I had lying around for my F150 were the correct size, with the same fitting placement, but the electrical connector was slightly different. Some of the bare pumps you can buy come with their own pigtails, so this normally won't be a problem. Note the part number on the pump: 6C34-9350-AA.
This is a VERY common Ford pump, you can get it in a lot of places new for $20-30. For example, if you have an early Escape or Ford Focus 2001-2008, of any engine size/type, this is the pump you need.

I just pirated a know good pump out of a 2002 V6 Escape, and it works!

 

Very nice. My hoses were broken, so I just punted and replaced the whole thing.