This procedure removes and replaces the fuel tank on a 2011-2014 Ford F-150 3.5L EcoBoost 4WD, including disconnecting fuel lines, electrical connections, and support straps.

Warnings

Tools required

Parts

• Fuel tank (if replacing) × 1 — Use OEM specification
• Fuel line O-rings × 4 — Use OEM specification
• Filler neck hose clamp × 1 — Use OEM specification
• Fuel tank vent hose (if damaged) × 1 — Use OEM specification
• Tank strap bolts (if corroded) × 4 — Use OEM specification

Preparation

1. Park vehicle on level, concrete surface with adequate ventilation. Set parking brake and place wheel chocks at front wheels.
2. Disconnect negative battery cable and isolate terminal away from battery post. Wait 2 minutes for system capacitors to discharge.
3. Relieve fuel system pressure: Remove fuel pump fuse (F18 in battery junction box), start engine and let it run until it stalls, then crank for 5 seconds. Reinstall fuse.
4. Siphon or drain fuel tank to less than 1/4 full using approved fuel transfer equipment. Store fuel in approved containers away from work area.
5. Raise vehicle on lift or jack stands to working height. Ensure vehicle is stable and secure on all four jack stands rated for vehicle weight.
6. Remove fuel tank skid plate if equipped (four 15mm bolts). Set aside hardware.

Procedure

1. 1

   Disconnect filler neck and vent lines
   Locate filler neck connection at left rear of tank. Loosen and remove filler neck hose clamp using 8mm socket. Disconnect filler neck hose from tank - may require twisting motion. Disconnect two EVAP vent lines from tank using quick-disconnect tool. Label lines if necessary for reinstallation.
2. 2

   Disconnect fuel pump module electrical connector
   Locate fuel pump module on top of tank (accessible from rear, driver side). Press release tab and disconnect main electrical connector from fuel pump module. Disconnect secondary connector for fuel level sender if equipped. Secure connectors away from tank.
3. 3

   Disconnect fuel supply and return lines
   Locate fuel lines at front of tank. Use appropriate size fuel line disconnect tool to release supply line (larger diameter, typically 3/8 inch). Catch residual fuel in drain pan. Disconnect return line using disconnect tool. Inspect O-rings and discard - use new O-rings during reinstallation. Cap open lines to prevent contamination.
   ⚠️Expect fuel spillage when disconnecting lines. Keep drain pan positioned and have absorbent materials ready. Fuel may spray if pressure was not fully relieved.
4. 4

   Position transmission jack under tank
   Position transmission jack with fuel tank adapter (or wide wooden block) directly under center of fuel tank. Raise jack until it just contacts tank bottom - do not lift tank yet. Ensure jack is stable and tank is balanced on jack surface.
5. 5

   Remove front tank mounting bracket
   Locate front tank mounting bracket bolts (two bolts securing bracket to frame). Using 15mm socket, remove both bracket mounting bolts. Remove bracket and set aside. Tank is now supported only by rear straps and transmission jack.
   Torque spec

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

   Remove tank strap bolts
   Locate two tank support straps at rear of tank. Each strap has one bolt at frame attachment point (driver and passenger side, 15mm head). Apply penetrating oil if bolts show corrosion. Support straps with one hand while removing bolts to prevent straps from falling. Remove driver side strap bolt first, then passenger side.
   ⚠Tank straps are under tension. Control straps as bolts are removed to prevent them from swinging down suddenly.
7. 7

   Lower and remove fuel tank
   Verify all lines, hoses, and electrical connectors are disconnected. Slowly lower transmission jack while guiding tank down. Watch for any snagged lines or wiring. Once tank is lowered approximately 12 inches, tilt rear of tank down and slide tank rearward to clear frame rails. Lower tank completely and roll transmission jack out from under vehicle.
   ⚠️Tank may still contain residual fuel. Keep tank level during removal. Have assistant help guide tank if working alone is difficult.
8. 8

   Remove fuel pump module (if servicing or replacing tank)
   If replacing tank or servicing fuel pump, remove lock ring securing fuel pump module. Use lock ring tool or brass punch and hammer, turning counterclockwise. Carefully lift pump module out at an angle to clear tank opening. Fuel level sender arm will swing out. Remove and inspect module seal - replace if damaged.
   ⚠Do not use steel tools that could create sparks near fuel tank opening. Use brass or plastic tools only.
9. 9

   Inspect and prepare new or cleaned tank
   If reusing tank, inspect interior for debris, rust, or contamination. Clean exterior of tank. If installing new tank, transfer heat shields and mounting brackets from old tank to new tank using existing hardware. Install fuel pump module into tank with new seal, align orientation marks, and tighten lock ring clockwise until secure.
10. 10

    Position tank for installation
    Place fuel tank on transmission jack. Raise tank to approximately 12 inches below frame. Tilt rear of tank down and slide tank forward between frame rails. Align tank with mounting points while continuing to raise jack. Guide filler neck area toward body opening.
11. 11

    Install tank straps and bracket
    Raise tank until strap mounting holes align with frame brackets. Install tank strap bolts and tighten to specification using torque wrench. Install front mounting bracket and torque bracket bolts to specification. Tank should now be secure - transmission jack is providing support only.
    Torque spec

    Tank Strap Bolts35 Nm (26 lb-ft)

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

    Connect fuel lines with new O-rings
    Install new O-rings on fuel line fittings - lubricate with clean engine oil. Push supply line fitting onto tank connection until it clicks. Tug line to verify lock engagement. Repeat for return line. If vehicle uses threaded fuel line fittings instead of quick-connects, torque to specification using proper fitting wrench.
    ⚠️Ensure fuel lines are fully locked. Improperly connected fuel lines will leak under pressure and can cause fire.
    Torque spec

    Fuel Line Fittings25 Nm (18 lb-ft)
13. 13

    Reconnect electrical and vent connections
    Connect fuel pump module main electrical connector - press until it clicks locked. Connect fuel level sender connector if equipped. Reconnect both EVAP vent lines to tank fittings - push until they click. Verify all connections are secure.
14. 14

    Install filler neck and final components
    Slide filler neck hose onto tank filler neck tube fully. Install hose clamp and position at center of hose. Torque clamp to specification - do not overtighten or hose may be damaged. Install fuel tank skid plate if equipped. Lower vehicle from jack stands.
    Torque spec

    Filler Neck Clamp4 Nm (3 lb-ft)
15. 15

    Pressure test and final checks
    Reconnect negative battery cable. Turn ignition to ON position (do not start) for 5 seconds to prime fuel system. Turn OFF, wait 5 seconds, repeat 3 times. Inspect all fuel line connections for leaks. Start engine and let idle for 2 minutes while inspecting underneath vehicle for any fuel seepage. Check for proper fuel gauge reading.
    ⚠️If any fuel leaks are detected, immediately shut off engine, disconnect battery, and repair leak before operating vehicle. Do not attempt to drive with fuel system leaks.

Reassembly

1. Always use new fuel line O-rings - never reuse old O-rings as they will cause leaks
2. Ensure fuel tank straps are not twisted during installation
3. Verify fuel pump module lock ring is fully tightened and module seal is properly seated
4. Route all fuel lines and wiring away from exhaust components and sharp edges
5. Tank strap bolt torque is critical - use calibrated torque wrench to prevent strap failure

Verification

• Perform three key-on cycles to pressurize fuel system and inspect all connections for leaks with engine off
• Start engine and verify it runs smoothly without stumbling or fuel starvation symptoms
• Inspect underneath vehicle while engine runs - look for fuel drips or wetness at all connection points
• Verify fuel gauge reads correctly and matches actual fuel level
• Test drive vehicle and recheck all connections after 10-15 miles of driving
• Check for fuel odor in cabin or around vehicle - any fuel smell indicates a leak that must be corrected immediately

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