Fuel Tank Strap

This procedure covers the removal and replacement of the fuel tank support straps on a 2011-2014 Ford F-150 with 5.0L V8 engine and 4WD, including fuel system depressurization and tank lowering.

Warnings

Tools required

Parts

• Fuel tank strap (driver side) × 1 — Ford BC3Z-9054-A or equivalent
• Fuel tank strap (passenger side) × 1 — Ford BC3Z-9054-B or equivalent
• Fuel line O-rings (assorted) × 1 — Use OEM specification
• Strap mounting hardware kit (if corroded) × 1 — Use OEM specification

Preparation

1. Park vehicle on level concrete surface outdoors or in well-ventilated shop with doors open
2. Ensure fuel tank is less than 1/4 full. If more than 1/4 tank, siphon or drive vehicle until low. Record gallons removed if siphoning for refill quantity
3. Verify fire extinguisher is accessible and you know how to operate it
4. Disconnect negative battery cable and isolate terminal away from battery post
5. Allow exhaust system to cool completely if vehicle was recently driven (minimum 1 hour)
6. Remove spare tire and jack assembly from under vehicle bed to access fuel tank area
7. Raise vehicle on lift or jack stands to provide 36 inches minimum clearance under frame. Support at manufacturer frame jacking points only
8. Place wheel chocks at front wheels to prevent rolling
9. Clean underside of vehicle around fuel tank area with degreaser to prevent dirt contamination during tank lowering

Procedure

1. 1

   Depressurize fuel system
   Locate fuel pump relay in power distribution box under hood (relay #27, 20A). Remove relay from socket. Attempt to start engine - it should crank but not start, or start briefly and stall. Crank engine for 10 seconds to consume remaining fuel pressure in lines. Turn ignition OFF. Fuel system is now depressurized.
   ⚠Do not skip this step. Pressurized fuel will spray when lines are disconnected, creating fire hazard and injury risk.
2. 2

   Access and disconnect fuel filler neck
   From driver side rear of vehicle, locate fuel filler neck behind rear wheel. Remove rubber shield if equipped. Locate filler neck hose clamp connecting filler neck to tank inlet pipe. Loosen hose clamp using flathead screwdriver or nut driver. Twist and pull filler neck hose off tank inlet - fuel residue will drain out. Place drain pan underneath. Disconnect filler neck vent line by squeezing tabs and pulling off connection at tank.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
3. 3

   Disconnect fuel line connections at tank
   Locate fuel supply and return lines at front of fuel tank. Lines connect with quick-disconnect fittings. Clean connections thoroughly with shop towel. Using appropriate size fuel line disconnect tool (typically 5/8" for supply line), insert tool into fitting and push inward while pulling line away from tank. Repeat for return line and any EVAP vapor lines. Place drain pan under connections - residual fuel will drain. Cap or plug open tank ports with clean shop towels to prevent contamination.
   ⚠Residual fuel under slight pressure may spray when disconnected. Keep face and body away from connection point. Have towels ready to catch fuel.
4. 4

   Disconnect electrical connectors
   Locate fuel pump module electrical connector on top of fuel tank (accessed from passenger side). Press connector lock tab and disconnect wiring harness. If vehicle has fuel tank pressure sensor or additional sensors, disconnect those connectors as well. Route wiring harnesses away from tank to prevent damage during lowering.
   ℹ️On some 2011-2012 models, connector may be difficult to access. Do not pull on wires - use connector release tab only.
5. 5

   Position support jack under fuel tank
   Position transmission jack or floor jack with wide wood board (2x10 minimum) directly under center of fuel tank. Raise jack until it just contacts tank bottom with light pressure. Tank should be supported but not lifting off straps yet. Verify jack is centered and stable - tank must not shift when straps are released.
   ⚠️Tank MUST be properly supported before removing straps. Unsupported tank will fall causing severe injury. Use transmission jack or wide support - floor jack alone is unstable.
6. 6

   Remove passenger side fuel tank strap
   Locate passenger side fuel tank strap. Strap is secured with two bolts to frame rail - one at front and one at rear of strap loop. Apply penetrating oil to bolt threads and allow to soak 5-10 minutes if hardware appears corroded. Using 15mm socket, remove front strap mounting bolt while supporting strap. Remove rear strap mounting bolt. Guide strap down and away from tank. Inspect strap for cracks, severe corrosion, or deformation - replace if damaged.
   ⚠On high-mileage or rust-belt vehicles, strap bolts may be seized or break during removal. Have replacement hardware available. If bolt breaks, remaining stud must be extracted before new strap can be installed.
   Torque spec

   Mounting Bolts34 Nm (25 lb-ft)
7. 7

   Remove driver side fuel tank strap
   Repeat strap removal process for driver side tank strap. Apply penetrating oil if needed. Remove front mounting bolt (15mm), then rear mounting bolt while supporting strap weight. Once second strap is removed, carefully control tank lowering using support jack. Lower tank approximately 6-8 inches - enough to access top of tank if needed, but not fully removing tank from vehicle.
   ⚠️As second strap is removed, entire tank weight transfers to jack. Maintain positive control of jack lowering. Do not allow tank to drop suddenly.
   Torque spec

   Mounting Bolts34 Nm (25 lb-ft)
8. 8

   Inspect tank straps and mounting points
   With tank lowered, inspect both tank straps for severe rust, cracks at bend points, or elongated mounting holes. Check strap cushions/insulators for deterioration. Inspect frame mounting points for rust damage, stripped threads, or cracks in mounting bosses. Wire brush frame mounting surfaces clean. If frame threads are damaged, repair with thread insert or helicoil before proceeding.
   ℹ️Strap failure is typically caused by corrosion at the bend points where strap wraps under tank. Surface rust is acceptable, but deep pitting or cracks require replacement.
9. 9

   Install new driver side strap
   Position new driver side fuel tank strap in place. Strap should have protective coating or cushion material where it contacts tank. If separate cushion insulators are used, install them on strap before positioning. Align strap to frame mounting holes. Install rear mounting bolt finger-tight first, then front mounting bolt finger-tight. Do not fully tighten yet - strap needs to adjust as tank is raised.
   ℹ️Verify strap orientation is correct - straps are side-specific on this vehicle. Part numbers differ for driver and passenger sides.
10. 10

    Install new passenger side strap and raise tank
    Position new passenger side strap with cushions in place. Install both mounting bolts finger-tight. Using support jack, slowly raise fuel tank until straps seat properly against tank bottom and frame. Tank should be centered in chassis with equal clearance on both sides. Once properly positioned, torque all four strap mounting bolts to specification in cross-pattern (driver rear, passenger front, driver front, passenger rear).
    ⚠Do not overtighten strap bolts beyond specification. Overtightening can deform tank or crack strap mounting bosses in frame.
    Torque spec

    Mounting Bolts34 Nm (25 lb-ft)
11. 11

    Reconnect electrical connections
    Reconnect fuel pump module electrical connector at top of tank. Push connector fully onto module until lock tab clicks into place. Tug gently to verify secure connection. Reconnect any additional sensor connectors (fuel tank pressure sensor, etc.). Verify no wiring is pinched between tank and chassis.
    ℹ️Connector must be fully seated and locked. Partial connection will cause fuel pump fault codes and no-start condition.
12. 12

    Reconnect fuel lines with new O-rings
    Install new O-rings on all fuel line connections at tank. Lightly lubricate new O-rings with clean gasoline or fuel-safe lubricant. Push each fuel line firmly onto tank port until it clicks - you should hear/feel a distinct click as quick-connect locks. Tug on each line to verify it's locked - line should not pull off. Reconnect EVAP vapor lines by pushing onto ports until locked.
    ⚠️New O-rings are MANDATORY. Old O-rings will leak causing fire hazard. Never reuse fuel line O-rings.
    ⚠Quick-disconnect fittings must click and lock fully. Partial connection will leak under pressure causing fuel spray and fire risk.
    Torque spec

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

    Reconnect filler neck and vent line
    Slide fuel filler neck hose fully onto tank inlet pipe. Position hose clamp over connection and tighten to specification using screwdriver or nut driver. Hose should be fully seated with no gaps. Connect filler neck vent line by pushing onto tank port until it clicks locked. Verify vent line has no kinks or restrictions.
    ⚠Filler neck must seal completely. Loose connection will cause fuel vapor odor and check engine light from EVAP system leak.
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)
14. 14

    Reinstall fuel pump relay and pressurize system
    Reconnect negative battery cable to battery post. Reinstall fuel pump relay (#27) in power distribution box. Turn ignition to ON position (do not start engine). Listen for fuel pump running for 2-3 seconds to pressurize system. Cycle ignition OFF then ON again 3-4 times. Inspect all fuel line connections and filler neck for leaks while system is pressurized. Look for wet spots or fuel drips.
    ⚠️CRITICAL LEAK CHECK: Any fuel leak creates immediate fire hazard. If any connection leaks, immediately turn ignition OFF, depressurize system, and repair leak before proceeding.

Reassembly

1. Remove support jack from under fuel tank only after verifying all connections are complete and leak-free
2. Reinstall spare tire carrier and jack assembly under vehicle bed
3. Lower vehicle from jack stands or lift
4. Add fuel to tank if siphoned during preparation - match quantity removed plus 2-3 gallons minimum for testing

Verification

• Start engine and verify it runs normally without fuel delivery issues or fault codes
• Inspect all fuel line connections, filler neck, and tank strap area for leaks with engine running
• Take vehicle for short test drive (5-10 minutes) including acceleration, braking, and turns to verify tank is secure and no leaks develop under dynamic conditions
• Re-inspect all connections after test drive for any seepage or drips
• Monitor for fuel odor in cabin or around vehicle for 24 hours after repair - any fuel smell indicates leak requiring immediate attention
• Verify no check engine light or fuel system fault codes using OBD-II scanner

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