Remove and replace the fuel pump module assembly from the fuel tank on a 2011-2014 Ford F-150 3.5L EcoBoost 4WD, requiring fuel tank access through bed-mounted service cover.

Warnings

Tools required

Parts

• Fuel pump module assembly × 1 — Use OEM Ford specification for 3.5L EcoBoost
• Fuel pump lock ring seal × 1 — Included with some pump modules, verify before installation
• Fuel line O-rings × 2 — Use OEM specification

Preparation

1. Park vehicle on level surface in well-ventilated outdoor area or shop with adequate ventilation system
2. Ensure fuel tank is 1/4 full or less; if necessary, siphon fuel into approved safety container using hand pump (never use mouth)
3. Place Class B fire extinguisher within immediate reach
4. Disconnect negative battery cable and wait 5 minutes to allow fuel pump control circuit to de-energize
5. Remove fuel filler cap to relieve tank pressure
6. Allow engine to cool completely if recently operated
7. Gather all tools and new parts; verify new fuel pump module matches original
8. Place absorbent pads or shop towels around work area in truck bed

Procedure

1. 1

   Relieve fuel system pressure
   With battery disconnected, locate the fuel rail Schrader valve on driver side fuel rail (if equipped) or proceed knowing residual pressure exists. Place shop towels around any connection point before loosening. Even with battery disconnected, residual pressure may be present. Allow any residual fuel to drain into towels before proceeding.
   ⚠️Fuel may spray when connections are loosened. Keep face and body clear of connection points.
2. 2

   Access fuel pump cover in truck bed
   Lower tailgate and remove bed mat or liner if equipped. Locate the fuel pump access cover on the bed floor, positioned toward front of bed on passenger side. The cover is a rectangular plastic panel secured by screws. Clean debris from around cover before proceeding.
   ⚠Dirt or debris falling into fuel tank during service can damage new pump or contaminate fuel system.
3. 3

   Remove access cover
   Remove the screws securing the fuel pump access cover using 8mm socket. There are typically 6-8 screws around perimeter. Carefully lift cover straight up and set aside. You should now see the top of the fuel pump module, fuel lines, and electrical connector.
   Torque spec

   Access Cover Screws5 Nm (3 lb-ft)
4. 4

   Disconnect electrical connector
   Locate the fuel pump electrical connector on top of the pump module. Press the locking tab and pull connector straight up and away from pump module. Inspect connector for corrosion or damage; clean if necessary with electrical contact cleaner.
   ℹ️Connector may be tight due to seal; use gentle wiggling motion while pulling if needed.
5. 5

   Disconnect fuel supply line
   Identify the fuel supply line (larger line) connected to pump module. Using appropriate size fuel line disconnect tool, press tool into collar while pulling line away from pump module. Fuel will drain from line; catch with shop towels. Inspect quick-connect fitting and O-ring for damage. Cap or plug open line to prevent contamination.
   ⚠Up to 1 cup of fuel may drain from supply line. Have absorbent materials ready.
6. 6

   Disconnect fuel return line and vapor line
   Using fuel line disconnect tool, disconnect the smaller return line (if equipped) and vapor line using same technique as supply line. These lines contain less fuel but still require absorbent materials. Note the position and routing of each line for proper reinstallation. Cap all open lines.
   ℹ️Some configurations may have combined vapor/return line. Verify your specific configuration before disconnecting.
7. 7

   Clean lock ring area
   Using non-metallic brush, thoroughly clean the area around the fuel pump lock ring and tank opening. Remove all dirt, rust, and debris that could fall into tank. Wipe clean with shop towel. This is critical to prevent contamination of new pump and fuel system.
   ⚠Do not use compressed air to clean area as this can blow debris into tank.
8. 8

   Remove fuel pump lock ring
   Install Ford fuel pump lock ring tool (310-069 or equivalent) onto lock ring tabs. The lock ring rotates counterclockwise to remove. Using a breaker bar or long ratchet handle, carefully rotate lock ring counterclockwise. Initial break-free may require significant force. Once loosened, continue rotating until lock ring can be lifted off. Remove and inspect lock ring seal.
   ⚠Do not strike lock ring with metal tools as this can create sparks near fuel vapors.
   ℹ️Lock ring is under slight spring tension from pump module seal. Control removal to prevent dropping into tank.
   Torque spec

   Fuel Pump Lock Ring78 Nm (58 lb-ft)
9. 9

   Remove fuel pump module
   Carefully lift fuel pump module straight up and out of fuel tank. Module will tilt as fuel level sensor float arm clears tank opening. Rotate module as needed to maneuver float arm and strainer through opening without forcing. Fuel will drain from module; allow to drain back into tank or into suitable container. Once clear, place old module on absorbent pads with opening facing up.
   ⚠Do not bend float arm or damage fuel level sensor during removal. These components are fragile.
   ⚠Several cups of fuel will drain from module. Have adequate absorbent materials positioned.
10. 10

    Inspect fuel tank opening and install new seal
    With pump removed, inspect inside edge of tank opening for debris, rust, or damage. Wipe clean with lint-free shop towel. Inspect tank opening seal surface for scratches or corrosion that could cause leaks. Remove old lock ring seal from tank and discard. Clean seal groove thoroughly. Install new lock ring seal onto tank, ensuring it seats properly in groove all the way around.
    ℹ️Do not allow any tools or debris to fall into open fuel tank.
11. 11

    Prepare new fuel pump module
    Remove new fuel pump module from packaging. Verify it matches original configuration including electrical connector orientation, fuel line positions, and float arm design. Install new O-rings onto fuel line connection points, lightly lubricating with clean gasoline if needed. Check that module seal/gasket is properly positioned on pump flange.
    ℹ️Some replacement modules come with fuel already in reservoir for priming. This is normal.
12. 12

    Install new fuel pump module
    Carefully lower new pump module into fuel tank opening, orienting module so electrical connector and fuel line fittings face correct direction (match original orientation). Tilt and rotate module as needed to guide float arm and strainer through opening without forcing. Once strainer is clear, align module flange with tank opening and press down evenly until module seats against seal.
    ⚠Ensure float arm moves freely and is not bent or binding against tank walls.
13. 13

    Install and torque lock ring
    Position lock ring over pump module flange, aligning tabs. Using lock ring tool and torque wrench, rotate lock ring clockwise while applying downward pressure to engage threads. Continue rotating until lock ring is snug, then torque to specification (78 Nm / 58 lb-ft) in clockwise direction. Verify lock ring is fully seated and pump module does not rotate.
    ⚠️CRITICAL: Proper lock ring torque is essential to prevent fuel leaks. Under-torquing can allow module to unseat; over-torquing can damage tank threads.
    Torque spec

    Fuel Pump Lock Ring78 Nm (58 lb-ft)
14. 14

    Connect fuel lines
    Install fuel supply line (larger line) onto pump module fitting by pushing straight in until a distinct click is heard and felt, indicating lock tabs have engaged. Gently pull on line to verify it is locked. Repeat for return line and vapor line. Ensure each connection is secure and O-rings are not visible in connection (indicating full engagement).
    ⚠️Improperly connected fuel lines will leak under pressure, creating fire hazard. Each line must click and lock positively.
    Torque spec

    Fuel Line Fittings25 Nm (18 lb-ft)
15. 15

    Connect electrical connector and test
    Connect electrical connector to fuel pump module, pressing down until locking tab clicks into place. Reconnect negative battery cable. Turn ignition key to ON position (do not start engine) to energize fuel pump. Listen for pump operation (2-3 second whirring sound). Immediately inspect all fuel line connections and lock ring area for leaks. If any leaks are observed, turn off ignition immediately and correct issue. Cycle ignition ON three times to build system pressure, checking for leaks after each cycle.
    ⚠️Any fuel leak must be corrected immediately before starting engine. Do not attempt to start engine if leaks are present.
16. 16

    Reinstall access cover
    Once leak check is complete and no leaks are found, clean any spilled fuel from access cover area. Position access cover over opening, aligning screw holes. Install screws and torque in star pattern to specification (5 Nm / 3 lb-ft) to ensure even seal compression. Reinstall bed mat or liner if equipped.
    Torque spec

    Access Cover Screws5 Nm (3 lb-ft)

Reassembly

1. Ensure all fuel line connections are secure and properly locked with no visible O-rings
2. Verify lock ring is torqued to specification and pump module does not rotate in tank
3. Confirm electrical connector is fully seated with locking tab engaged
4. Access cover must be properly sealed to prevent water intrusion into fuel tank
5. Clean up any spilled fuel and dispose of absorbent materials according to local regulations

Verification

• Turn ignition to ON position (engine off) and listen for fuel pump operation; pump should run for 2-3 seconds
• Inspect all connections for fuel leaks with ignition ON and system pressurized
• Start engine and verify it runs smoothly without stumbling or surging, indicating proper fuel delivery
• Check fuel gauge operation to confirm fuel level sender is functioning correctly
• Perform final leak inspection with engine running at idle; check fuel pump module area, all line connections, and access cover seal
• Road test vehicle under various loads to verify proper fuel system operation; monitor for any fuel odors in cab or bed area
• After test drive, perform cold inspection of all connections and access cover area for any signs of seepage

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