This procedure covers removal and replacement of the fuel level sensor in the fuel tank assembly, requiring tank lowering for access.

Warnings

Tools required

Parts

• Fuel level sensor × 1 — Use OEM Ford part for proper gauge calibration
• Fuel tank O-ring seal × 1 — Use OEM specification
• Fuel line O-rings × 4 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable and wait 5 minutes for system capacitors to discharge
3. Relieve fuel system pressure by removing fuel pump relay (location: power distribution box under hood, relay R3) and attempting to start engine until it stalls
4. If tank is more than 1/4 full, siphon or drain fuel into approved container to reduce weight
5. Raise vehicle securely on safety stands at all four corners to provide adequate working clearance
6. Remove spare tire and lower spare tire carrier if equipped to improve access

Procedure

1. 1

   Disconnect fuel filler neck
   Locate the fuel filler neck connection on driver side rear of tank. Loosen hose clamp using flathead screwdriver or socket. Slide clamp back along filler neck hose and carefully twist and pull hose off tank inlet. Be prepared for residual fuel spillage.
   Torque spec

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

   Disconnect EVAP and vent lines
   Locate EVAP canister vent line and vapor lines on top of tank near filler neck. Use fuel line disconnect tool to release quick-connect fittings. Press the tool onto the line and pull the line away from the tank fitting. Mark or photograph line positions for reassembly reference.
   ℹ️EVAP lines are plastic and can be brittle. Use appropriate size disconnect tool to avoid breaking fittings.
3. 3

   Disconnect fuel supply and return lines
   Locate fuel supply line (larger diameter) and return line on front of fuel tank. Use appropriate size fuel line disconnect tool for each fitting. Insert tool completely around line, press firmly, and pull line straight off tank fitting. Cap open lines immediately to prevent contamination.
   ⚠Residual fuel pressure may cause fuel spray. Have rags ready to catch fuel.
   Torque spec

   Fuel Line Fittings25 Nm (18 lb-ft)
4. 4

   Disconnect electrical connectors
   Locate fuel pump module electrical connector on top front of tank. Press release tab and disconnect connector. Disconnect fuel tank pressure sensor connector if equipped. Secure connectors away from tank to prevent damage during lowering.
   ℹ️Verify battery is disconnected before handling electrical connectors.
5. 5

   Support fuel tank
   Position transmission jack or equivalent tank support directly under center of fuel tank. Raise jack until it just contacts tank bottom. Use wood block or adapter to spread load and prevent tank damage. Secure tank to jack with strap or chain to prevent shifting.
   ⚠Tank may still contain 10+ gallons of fuel even if partially drained. Ensure jack capacity is adequate.
6. 6

   Remove tank mounting straps
   Locate two fuel tank mounting straps running front to rear under tank. Remove rear mounting bolts from each strap using socket and ratchet. Swing straps down and away from tank. Support straps to prevent them from interfering with tank removal.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
7. 7

   Lower fuel tank
   Carefully lower transmission jack, dropping tank approximately 12 inches to expose top of fuel pump module. Lower slowly and check frequently that all lines and connectors are clear. Tank does not need to be fully removed for sensor access.
   ⚠Have assistant guide tank and verify no lines or wires are caught as tank lowers.
8. 8

   Remove fuel pump module lock ring
   Clean debris from top of fuel tank around pump module to prevent contamination. Using lock ring tool, rotate fuel pump module lock ring counterclockwise until it releases. Some designs may use tabs that must be tapped counterclockwise with brass punch and hammer instead of lock ring tool.
   ⚠️Do not use steel punch or create sparks near open fuel tank. Use only brass or plastic tools.
9. 9

   Remove fuel pump module assembly
   Carefully lift fuel pump module straight up and out of tank opening. Tilt assembly slightly to work float arm and fuel level sensor out without bending. Note orientation of module for reinstallation. Place module on clean work surface with fuel level sensor accessible.
   ⚠Float arm and fuel level sensor are fragile. Do not bend or force during removal.
10. 10

    Replace fuel level sensor
    Locate fuel level sensor on side of pump module assembly. Disconnect sensor electrical connector from module harness. Remove sensor mounting clip or fastener securing sensor to float arm assembly. Install new sensor in exact same position, ensuring float arm moves freely through full range of motion without binding. Connect electrical connector until it clicks.
    ℹ️Verify float arm moves smoothly from empty to full position after sensor installation.
11. 11

    Reinstall fuel pump module
    Inspect and replace tank O-ring seal on pump module if worn or damaged. Align module with tank opening, ensuring float arm and sensor enter without interference. Push module straight down into tank until it seats against O-ring. Install lock ring and rotate clockwise until fully seated and locked.
    ⚠Ensure lock ring is fully engaged. Improper seating will cause fuel leaks and pressure loss.
12. 12

    Raise and secure fuel tank
    Raise transmission jack to lift tank back into position against vehicle underbody. Align tank mounting strap holes with frame holes. Install mounting strap bolts and tighten to specification. Verify tank is properly seated before removing jack support.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
13. 13

    Reconnect all lines and connectors
    Reconnect fuel supply and return lines to tank fittings, pushing straight on until they click into place. Tug lines to verify secure connection. Install new O-rings on fuel line fittings if provided with sensor kit. Reconnect EVAP and vent lines in proper positions. Reconnect fuel pump module electrical connector and pressure sensor connector.
    Torque spec

    Fuel Line Fittings25 Nm (18 lb-ft)
14. 14

    Reconnect filler neck and finalize
    Slide filler neck hose fully onto tank inlet. Position hose clamp over connection point and tighten to specification. Reconnect negative battery cable. Reinstall fuel pump relay. Lower vehicle from safety stands.
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)

Reassembly

1. Verify all fuel line connections are secure with no visible leaks
2. Ensure all electrical connectors are fully seated and locked
3. Confirm fuel tank is properly supported by mounting straps with bolts torqued to specification
4. Reinstall spare tire carrier and spare tire if removed

Verification

• Turn ignition to ON position (do not start) and listen for fuel pump priming for 2-3 seconds
• Cycle ignition ON and OFF three times to pressurize fuel system, then inspect all connections for leaks
• Start engine and verify it runs normally without fuel delivery issues
• Check fuel gauge operation: it should display current fuel level within 1/8 tank accuracy
• Test drive vehicle and verify fuel gauge responds to fuel consumption, moving toward empty as fuel is used
• Recheck all connections underneath vehicle for any fuel seepage after test drive

More procedures for this vehicle