Replace the fuel level sensor in the fuel tank by removing the truck bed to access the fuel pump module assembly.

Warnings

Tools required

Parts

• Fuel level sensor × 1 — Use OEM specification or quality aftermarket
• Fuel pump module O-ring seal × 1 — Use OEM specification
• Fuel line O-rings × 4 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Disconnect negative battery cable and wait 10 minutes for fuel pump to de-energize
3. Relieve fuel system pressure by removing fuel pump fuse and attempting to start engine until it stalls
4. If tank is more than 3/4 full, siphon fuel down to approximately 1/2 tank to reduce weight and spill potential
5. Gather all required tools and new parts including O-rings
6. Ensure adequate ventilation in work area and remove all ignition sources

Procedure

1. 1

   Remove truck bed mounting hardware
   Starting at the rear of the bed, locate and remove the 6-8 bed mounting bolts (3-4 per side) that secure the bed to the frame. These are typically 15mm or 18mm bolts. Spray penetrating oil on rusty bolts and allow to soak. Disconnect the trailer wiring harness connector near the rear bumper and any bed lighting connectors.
   Torque spec

   Mounting Bolts34 Nm (25 lb-ft)
2. 2

   Lift and remove truck bed
   With at least one helper, carefully lift the bed straight up and off the frame. The bed typically weighs 300-400 lbs. Place the bed on padded sawhorses or moving blankets to prevent damage. Ensure fuel filler neck disconnects from the bed-mounted filler door as the bed is lifted.
   ⚠Lift with your legs, not your back. The bed is heavier than it appears and awkward to handle.
3. 3

   Clean fuel tank access area
   With the bed removed, the fuel tank is now visible. Use a wire brush and shop towels to clean debris, dirt, and corrosion from around the fuel pump module access cover on top of the tank. This prevents contamination from entering the tank when opened.
   ℹ️Any debris that falls into the fuel tank can damage the new sensor or fuel pump. Take extra time to thoroughly clean this area.
4. 4

   Disconnect fuel lines and electrical connector
   Locate the fuel supply and return lines at the fuel pump module. Use the appropriate fuel line disconnect tools to separate the quick-connect fittings. Have a drain pan ready to catch residual fuel. Disconnect the electrical connector from the fuel pump module by pressing the locking tab and pulling straight away.
   ⚠Fuel will spill from the lines. Ensure drain pan is positioned correctly and have shop towels ready.
5. 5

   Remove fuel pump module lock ring
   Using the lock ring tool, turn the fuel pump module lock ring counterclockwise to unlock it. The lock ring may be tight due to corrosion. Once loosened, remove the lock ring completely and set aside with the old O-ring seal.
   ⚠Do not use a hammer and chisel to remove the lock ring as this can create sparks or damage the tank.
6. 6

   Remove fuel pump module assembly
   Carefully lift the fuel pump module assembly out of the tank. Tilt it slightly to clear the tank opening while keeping the float arm from catching on the tank walls. The module will have fuel in it, so keep the drain pan underneath. Set the module on clean shop towels in a clean work area.
   ℹ️The float arm is delicate. Avoid bending or damaging it during removal.
7. 7

   Remove old fuel level sensor
   With the pump module on the bench, locate the fuel level sensor attached to the side of the module. Disconnect the internal electrical connector. Remove the retaining clips or screws (typically 2-3) that secure the sensor to the module housing. Carefully slide the sensor and float arm assembly out of the module.
   Torque spec

   Cover Screws14 Nm (10 lb-ft)
8. 8

   Install new fuel level sensor
   Install the new fuel level sensor into the pump module housing, ensuring the float arm moves freely through its full range of motion without binding. Secure with the retaining clips or screws to specified torque. Connect the internal electrical connector until it clicks into place.
   Torque spec

   Cover Screws14 Nm (10 lb-ft)
9. 9

   Inspect and clean tank opening
   Before reinstalling the module, inspect the fuel tank opening for debris or damage. Wipe the sealing surface clean with a lint-free cloth. Inspect the inside of the tank opening for any debris and remove if present.
10. 10

    Install new O-ring and reinstall pump module
    Install the new fuel pump module O-ring seal onto the tank opening. Ensure it seats properly in the groove. Carefully lower the pump module assembly back into the tank, aligning the orientation marks. Rotate the module to ensure proper alignment with the tank shape and fuel level sender positioning.
    ℹ️The module must be oriented correctly for the fuel level sensor to read accurately. Note the original position before removal.
11. 11

    Install and secure lock ring
    Place the lock ring over the fuel pump module and hand-tighten it clockwise. Use the lock ring tool to tighten the ring securely until it stops against the locking tabs. Do not over-torque as this can damage the plastic components.
    ⚠Over-tightening the lock ring can crack the fuel pump module housing or tank opening.
12. 12

    Reconnect fuel lines with new O-rings
    Install new O-rings on all fuel line fittings. Push the fuel supply and return lines onto the module connections until they click into place. Tug gently on each line to verify they are fully seated and locked. Reconnect the electrical connector to the fuel pump module.
    ℹ️New O-rings are critical for preventing fuel leaks. Do not reuse old O-rings.
    Torque spec

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

    Reinstall truck bed
    With at least one helper, carefully lift the bed and position it back onto the frame rails, aligning the bolt holes. Guide the fuel filler neck back into position. Install all bed mounting bolts and tighten to specification in a cross-pattern to ensure even seating. Reconnect trailer wiring and any bed lighting connectors.
    Torque spec

    Mounting Bolts34 Nm (25 lb-ft)
14. 14

    Restore power and prime fuel system
    Reconnect the negative battery cable. Reinstall the fuel pump fuse. Turn the ignition key to the ON position (without starting) for 5 seconds, then OFF. Repeat this 3-4 times to allow the fuel pump to prime the system and check for leaks around the fuel pump module connections.

Reassembly

1. Torque all fasteners to specification using a calibrated torque wrench
2. Verify all electrical connectors are fully seated and locked
3. Double-check that fuel line quick-connect fittings are properly engaged
4. Ensure bed mounting bolts are tightened in a cross-pattern for even pressure distribution

Verification

• Start the engine and verify it runs smoothly without fuel starvation issues
• Check around the fuel pump module for any fuel leaks while the engine is running
• Verify the fuel gauge reads correctly on the instrument cluster (should show current tank level)
• Test the fuel gauge accuracy by adding a known quantity of fuel and confirming the gauge moves appropriately
• Inspect all bed mounting points to ensure the bed is secure with no movement
• Road test the vehicle and monitor fuel gauge operation through various fuel levels

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