Replace the fuel pump module assembly by accessing it through the bed-mounted service cover on 2011-2014 Ford F-150 5.0L V8 4WD models.

Warnings

Tools required

Parts

• Fuel pump module assembly × 1 — Motorcraft PFS-566 or equivalent
• Fuel pump module O-ring seal × 1 — Usually included with pump assembly
• Fuel tank access cover gasket × 1 — Ford BL3Z-9N567-A or equivalent

Preparation

1. Park vehicle on level surface and engage parking brake. Chock rear wheels.
2. Ensure fuel tank is less than half full to minimize spillage. If tank is full, siphon fuel into approved containers in well-ventilated area.
3. Disconnect negative battery cable and isolate from battery terminal. Wait 5 minutes for airbag system to discharge.
4. Remove rear seat bottom cushion by releasing two front retaining clips and lifting upward and forward.
5. Locate fuel pump access cover on cab floor beneath rear seat. Clean area thoroughly around access cover to prevent contamination entering fuel tank.
6. Have Class B fire extinguisher within immediate reach throughout entire procedure.

Procedure

1. 1

   Relieve fuel system pressure
   Locate the fuel pump driver module (FPDM) connector under the rear seat area near the access cover. Disconnect the FPDM electrical connector. Reconnect the negative battery cable. Start the engine and allow it to run until it stalls from fuel starvation (typically 15-30 seconds). Attempt to restart engine to verify all pressure is relieved; it should not start. Turn ignition off. Disconnect negative battery cable again and isolate.
   ⚠️Engine will stall suddenly when fuel pressure depletes. This is normal and expected.
2. 2

   Remove fuel pump access cover
   Using a Phillips screwdriver, remove the screws securing the fuel pump access cover to the cab floor. There are typically 8-10 screws around the perimeter. Lift the access cover and gasket from the floor pan. Inspect the gasket for damage; replace if torn or compressed. Set cover aside.
3. 3

   Disconnect fuel pump electrical connector
   Locate the large electrical connector on top of the fuel pump module. Press the release tab and carefully pull the connector straight up to disconnect. Do not twist or bend connector. If connector is difficult to remove, gently rock it side to side while pulling upward.
   ⚠Connector may be brittle from heat exposure. Use care to avoid breaking release tab.
4. 4

   Disconnect fuel supply line
   Identify the fuel supply line (larger diameter line, typically 5/16 inch) connected to the pump module. Place shop towels around the connection to absorb residual fuel. Using the appropriate size fuel line disconnect tool, insert the tool into the quick-connect fitting and push inward while pulling the fuel line away from the pump module. Fuel will drain from the line; capture with towels. Cap the fuel line with a clean plug or wrap with plastic to prevent contamination.
   ⚠Expect 2-4 ounces of fuel to spill from supply line despite pressure relief. Have towels ready.
5. 5

   Disconnect fuel return line (if equipped)
   Some 2011-2014 F-150 configurations have a fuel return line (smaller diameter). If present, disconnect using the same procedure as the supply line with appropriate size disconnect tool. If your vehicle has only one fuel line, proceed to next step.
   ℹ️Most 5.0L V8 models use returnless fuel system with only supply line.
6. 6

   Remove fuel pump lock ring
   Position the fuel pump lock ring tool onto the lock ring tabs. The lock ring has multiple tabs around its circumference. Ensure tool is fully engaged on at least two opposite tabs. Rotate the lock ring counterclockwise (when viewed from above) using steady pressure. The ring may be tight initially; do not use excessive force that could break tabs. Once loosened, continue rotating by hand until lock ring is completely free. Lift lock ring out of tank opening.
   ⚠Lock ring threads are NOT traditional screw threads. Ring rotates approximately 1/8 to 1/4 turn to unlock. Do not force rotation beyond unlock point.
   ⚠Inspect lock ring tabs for damage. Replace lock ring if tabs are broken or bent.
7. 7

   Remove fuel pump module assembly
   Carefully lift the fuel pump module straight up out of the fuel tank opening. The module assembly is approximately 10-12 inches tall. Tilt the module slightly as needed to clear the tank opening, but keep it as vertical as possible to minimize fuel spillage. The fuel level sender float arm will extend from the side; take care not to bend or damage it. Once clear of the tank, tilt the module over the tank opening to drain remaining fuel back into tank. Place the old module in a suitable container to catch dripping fuel.
   ⚠Fuel pump module weighs approximately 2-3 pounds when empty. Expect 4-6 pounds with residual fuel.
   ⚠Do NOT bend the fuel level sender float arm. Bending will cause inaccurate fuel gauge readings.
8. 8

   Remove and inspect tank seal
   Remove the large rubber O-ring seal from the groove in the top of the fuel tank opening. This seal may stick to the tank. Use a flat blade screwdriver if needed to gently pry it out, being careful not to scratch the sealing surface on the tank. Inspect the tank opening sealing surface for corrosion, debris, or damage. Clean the sealing surface thoroughly with shop towels. Any debris or corrosion will cause fuel leaks.
   ⚠Do not reuse old O-ring seal. Always install new seal supplied with replacement pump module.
9. 9

   Prepare new fuel pump module
   Unpack the new fuel pump module assembly. Verify the new module matches the old module configuration, particularly the electrical connector style and fuel line connection type. Install the new O-ring seal onto the fuel pump module by stretching it over the top and seating it in the groove on the module body. Ensure the O-ring is properly seated all around with no twists or gaps. Lightly lubricate the O-ring with clean engine oil or fresh gasoline to aid installation.
   ℹ️Some replacement modules may include updated components. Verify part application matches your vehicle year and configuration.
10. 10

    Install new fuel pump module
    Carefully lower the new fuel pump module into the fuel tank opening. The module will only fit in one orientation; align the module so it fits into the tank without forcing. Guide the fuel level sender float arm into the tank carefully to avoid bending. Push the module straight down until the O-ring seal contacts the tank opening and the module flange seats against the tank. Ensure the module is fully seated with the alignment marks (if present) properly positioned.
    ⚠Do not rotate module once O-ring contacts tank as this can dislodge or twist the seal.
11. 11

    Install and torque lock ring
    Position the fuel pump lock ring over the fuel pump module with the tabs aligned to the slots in the tank flange. Press the lock ring down and rotate clockwise using the lock ring tool until it stops. Using a torque wrench with the lock ring tool, torque the lock ring to specification. Verify the lock ring is fully seated and locked in position by attempting to rotate it counterclockwise slightly; it should not move.
    ⚠️Proper lock ring torque is CRITICAL for fuel system safety. Under-torquing can cause fuel leaks and fire hazard. Over-torquing can crack the tank flange.
12. 12

    Connect fuel lines
    Remove the protective cap or covering from the fuel supply line. Push the fuel supply line straight onto the pump module quick-connect fitting until you hear and feel a distinct click. Gently pull on the line to verify it is locked in place; it should not pull off. If a return line is present, connect it using the same procedure. Wipe away any spilled fuel with shop towels.
    ⚠Quick-connect fittings must click audibly when properly seated. If no click is heard, disconnect and retry.
13. 13

    Connect electrical connector
    Align the electrical connector with the fuel pump module connector. Push the connector straight down onto the module until the locking tab clicks into place. Verify the connection is secure by gently pulling upward on the connector; it should not separate.
    ℹ️Ensure connector is fully seated. Partial connection will cause no-start condition or fuel pump failure codes.
14. 14

    Install access cover
    Position the new access cover gasket (or cleaned original if in good condition) on the cab floor pan around the access opening. Align the access cover over the gasket and opening. Install all access cover screws by hand first to ensure proper alignment. Torque screws in a criss-cross pattern to specification to ensure even gasket compression.
    ℹ️Criss-cross tightening pattern prevents gasket distortion and potential fuel vapor leaks into cabin.
15. 15

    Prime fuel system and check for leaks
    Reconnect the negative battery cable. Turn the ignition key to the ON position (do not start engine) and listen for the fuel pump to run for approximately 2 seconds, then shut off. This primes the fuel system. Cycle the ignition OFF, wait 5 seconds, then ON again. Repeat this cycle 4-5 times to fully prime the system. Have an assistant check the access cover area for fuel leaks while you cycle the ignition. If no leaks are observed, start the engine and verify it runs normally. Recheck for leaks.
    ⚠️If any fuel leaks are observed, immediately turn off ignition, disconnect battery, and identify source. Do not operate vehicle with fuel leaks.
    ⚠First start may take longer cranking than normal as system pressure builds. Do not crank for more than 15 seconds at a time.

Reassembly

1. Reinstall rear seat bottom cushion by engaging rear hooks first, then pressing down on front edge until retaining clips engage with audible click.
2. Remove wheel chocks and verify parking brake releases properly.
3. Properly dispose of old fuel pump module according to local regulations. Most auto parts stores accept old fuel pumps for recycling.
4. Clean up any spilled fuel immediately with absorbent materials. Dispose of fuel-soaked towels in sealed metal container away from ignition sources.

Verification

• Start engine and verify smooth idle with no misfires or hesitation. Engine should start within normal cranking time after fuel system is primed.
• Check fuel gauge operates correctly and displays accurate fuel level. Gauge should move smoothly, not erratically.
• Test drive vehicle and verify normal acceleration and no fuel delivery problems under load.
• After test drive, raise rear seat and inspect access cover area for any signs of fuel leaks or wetness. Strong fuel odor indicates leak.
• Check for diagnostic trouble codes using scan tool. No fuel system codes should be present.
• Monitor fuel gauge over next few days to ensure sender float arm was not damaged during installation. Gauge readings should be consistent with actual fuel level.

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