I had a similar problem on my 1999 Zetec and went through the same thought process as you are now.
I could only see 2 ways.
One is to cut the frame above the tank and then make some brackets to bolt to back together again. However this destroys the integrity of the frame and as I also wanted to remove the fuel level sensor and check the inside of the tank, I chose the other route.
Which is to drop the tank out of the bottom by cutting the floor and then replacing it with brackets to bolt the tank up from underneath so that it becomes easily removable in future.
It's a sod of a job to do especially on your own but it is doable. I cursed an awful lot during the process.
I did consider buying a new tank and custom made bracket for the replacement but as the tank was in excellent condition, I replaced it and made my own bracket to put it back together.
If you go down the same route, I may be able to give you some tips.
Edit........ If you go down my route, I hope your tank is fairly empty because if your pump is completely dead it will be very difficult to drain the tank and dropping a full tank will be very difficult.
Are you absolutely certain the pump is dead. Have you run separate power and earth cables to test it?
Last edited by IvorMog; 28/01/21 09:44 AM.
