Fuel Filler Neck

This procedure covers the removal and replacement of the fuel filler neck on a 2011-2014 Ford F-150 with 3.5L EcoBoost engine and 4WD, including disconnecting fuel vapor hoses and removing the filler neck assembly from the body.

Warnings

Tools required

Parts

• Fuel filler neck assembly × 1 — Use OEM specification
• Fuel filler neck grommet × 1 — Use OEM specification
• Hose clamps (if damaged) × 2 — Use OEM specification
• Vapor hose (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Ensure fuel tank is less than half full to minimize fuel spillage
3. Disconnect negative battery cable and wait 2 minutes
4. Raise and support rear of vehicle on jack stands at frame rails
5. Remove driver's side rear wheel for better access to filler neck area
6. Remove driver's side rear wheel well liner by removing plastic fasteners

Procedure

1. 1

   Access fuel door area
   Open the fuel door and remove the fuel cap. From inside the bed, locate and remove the access cover on the driver's side bedside panel if equipped. This may require removing trim fasteners or screws.
   Torque spec

   Cover Screws12 Nm (9 lb-ft)
2. 2

   Disconnect filler neck hose clamp at fuel tank
   From underneath the vehicle near the fuel tank, locate the large hose clamp connecting the filler neck to the fuel tank. Use hose clamp pliers or a flat blade screwdriver to loosen and reposition the hose clamp away from the connection point. Be prepared for residual fuel spillage.
   ⚠Have drain pan positioned under connection point. Expect 1-2 cups of fuel to drain.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
3. 3

   Disconnect vapor hoses
   Locate the EVAP vapor hose connections on the filler neck assembly. These are typically quick-disconnect fittings. Press the release tabs and pull the hoses away from the filler neck. Mark hose positions if necessary for reinstallation.
4. 4

   Remove filler neck mounting bolts
   Locate the filler neck mounting bolts that secure the neck to the body panel at the fuel door opening. There are typically 2-3 bolts accessible from the fuel door area. Remove these bolts and retain them for reinstallation.
   Torque spec

   Filler Neck Bolts10 Nm (7 lb-ft)
5. 5

   Remove bracket bolts if equipped
   Check for any support brackets along the filler neck route between the body panel and fuel tank. Remove any bracket bolts securing the filler neck to the frame or body. These brackets help support the neck and prevent movement.
   Torque spec

   Bracket Bolts23 Nm (17 lb-ft)
6. 6

   Separate filler neck from fuel tank
   From underneath the vehicle, carefully twist and pull the filler neck tube away from the fuel tank inlet. The rubber grommet may stick to either the neck or tank. Work the neck free gently to avoid tearing the grommet.
   ⚠Do not use excessive force. If stuck, apply penetrating oil around the grommet and wait 10 minutes.
7. 7

   Remove filler neck assembly
   Maneuver the filler neck assembly out through the wheel well opening. This may require rotating and angling the neck to clear body panels and frame components. The neck exits through the driver's side rear wheel well area.
8. 8

   Inspect and replace grommet
   Remove the rubber grommet from the old filler neck or from the fuel tank inlet. Inspect for cracks, tears, or hardening. Install the new grommet onto the fuel tank inlet, ensuring it seats properly in the tank opening. Apply a small amount of soapy water to ease installation if needed.
9. 9

   Install new filler neck assembly
   Route the new filler neck through the wheel well opening and position it into the body panel opening at the fuel door. Insert the lower end of the neck into the fuel tank grommet, twisting gently to seat it fully. Ensure the neck is properly aligned with all mounting points.
10. 10

    Install filler neck mounting bolts
    Install and torque the filler neck mounting bolts at the fuel door opening. Start all bolts by hand, then tighten in a cross pattern to the specified torque value to ensure even seating against the body panel.
    Torque spec

    Filler Neck Bolts10 Nm (7 lb-ft)
11. 11

    Install bracket bolts
    Reinstall any support bracket bolts along the filler neck route. Ensure brackets properly support the neck without creating stress points. Torque bracket bolts to specification.
    Torque spec

    Bracket Bolts23 Nm (17 lb-ft)
12. 12

    Connect and secure filler neck to fuel tank
    Verify the filler neck is fully seated into the fuel tank grommet. Position the hose clamp over the connection point and tighten to specification. Ensure the clamp is positioned on the ribbed section of the filler neck for proper sealing.
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)
13. 13

    Reconnect vapor hoses
    Reconnect the EVAP vapor hoses to the filler neck assembly, ensuring each quick-disconnect fitting clicks into place. Gently tug on each hose to verify secure connection. Verify hoses are routed properly without kinks or sharp bends.
14. 14

    Reinstall access covers and wheel components
    Reinstall any access covers or trim panels inside the bed area, torquing screws to specification if applicable. Reinstall the wheel well liner with all plastic fasteners. Reinstall the rear wheel and torque lug nuts to specification (use vehicle's manual for lug nut torque).
    Torque spec

    Cover Screws12 Nm (9 lb-ft)

Reassembly

1. Reconnect negative battery cable
2. Lower vehicle from jack stands
3. Check all connections are tight and properly seated
4. Verify fuel cap is installed properly after testing

Verification

• Add 2-3 gallons of fuel at a gas station and monitor for leaks around filler neck connections
• Check for fuel odor around the fuel door area and underneath the vehicle
• Verify no fuel leakage at the tank connection point after fueling
• Confirm EVAP system has no codes by scanning with OBD-II scanner after 2-3 drive cycles
• Test fuel door operation and ensure filler neck cap seals properly

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