Fuel Tank

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

Warnings

Tools required

Parts

• Fuel tank strap bolts (if corroded) × 4 — OEM or Grade 8 equivalent
• Fuel filler neck hose clamp × 1 — Use OEM specification
• Fuel line O-rings × 4 — Use OEM specification
• Fuel tank shield hardware (if corroded) × 1 — Use OEM specification
• EVAP line grommets (if damaged) × 2 — Use OEM specification

Preparation

1. Ensure fuel tank is less than 1/4 full. If tank contains more fuel, siphon or drive vehicle until fuel level is low to reduce weight and spillage risk.
2. Park vehicle on level, solid ground in a well-ventilated outdoor area or shop with adequate ventilation.
3. Disconnect negative battery cable and isolate it away from battery terminal.
4. Allow vehicle to sit for at least 30 minutes after battery disconnect to allow fuel system pressure to bleed down.
5. Chock front wheels securely.
6. Raise rear of vehicle using floor jack and support on jack stands rated for vehicle weight at manufacturer-specified jacking points on frame rails.
7. Position Class B fire extinguisher within immediate reach of work area.
8. Place drain pan and approved fuel storage containers near work area.
9. Put on fuel-resistant gloves and safety glasses before beginning work.

Procedure

1. 1

   Relieve residual fuel system pressure
   Locate the fuel pump driver module connector on the frame rail near the fuel tank. Disconnect the electrical connector. Attempt to start the engine; it should crank but not start, or start briefly and stall. This confirms fuel pressure is relieved. Leave connector disconnected for remainder of procedure.
   ⚠Battery must be disconnected before disconnecting fuel pump module to prevent fuel pump activation.
2. 2

   Remove fuel tank shield
   Remove the plastic fuel tank shield/skid plate covering the front and sides of the fuel tank. Remove approximately 8-10 screws around perimeter using 8mm socket. Shield may be in multiple pieces. Set aside shield and hardware.
   Torque spec

   Cover Screws14 Nm (10 lb-ft)
3. 3

   Disconnect fuel filler neck
   Locate the fuel filler neck hose connection at the rear driver side of the tank. Loosen the hose clamp using a flathead screwdriver or 8mm socket. Slide clamp back on hose. Twist and pull the filler neck hose off the tank inlet pipe. Expect residual fuel spillage; have rags ready.
   ⚠Fuel will spill from filler neck. Have drain pan positioned to catch spillage.
   Torque spec

   Filler Neck Clamp4 Nm (3 lb-ft)
4. 4

   Disconnect EVAP and vent lines
   Locate the EVAP vapor lines and vent lines on top of the fuel tank (typically near the front). These are plastic quick-connect fittings. Press the release tabs and pull lines straight out from tank fittings. There are typically 2-3 lines. Label or photograph connections for reassembly reference.
5. 5

   Disconnect main fuel supply and return lines
   Locate the metal fuel supply and return lines at the front of the fuel tank. These use spring-lock couplings. Use the appropriate size fuel line disconnect tool (typically 3/8" for supply, 5/16" for return). Slide tool over line and push toward fitting while pulling line away from tank. Expect fuel spillage from lines into drain pan. Cap or plug lines if available to minimize spillage.
   ⚠Fuel under residual pressure may spray when lines are disconnected. Wear safety glasses and keep face away from connection point.
6. 6

   Disconnect fuel pump module electrical connector
   Locate the main fuel pump module electrical connector on top of the fuel tank (typically center or driver side). Press release tab and disconnect the multi-pin connector. On some models there may be a secondary fuel level sender connector; disconnect this as well.
7. 7

   Support fuel tank with transmission jack
   Position transmission jack or floor jack with wide wood block under center of fuel tank. Raise jack until it just contacts tank and takes slight weight, but tank is still supported by straps. Ensure tank is balanced and stable on jack before proceeding.
   ⚠️Tank must be properly balanced on jack. An unstable tank can fall and cause serious injury. Use a transmission jack with wide support surface or a substantial wood block.
8. 8

   Remove rear fuel tank strap
   Locate the rear fuel tank strap bolt on the driver side frame rail. Using a 15mm socket and ratchet, remove the strap bolt. The strap will swing down but tank remains supported by front strap and jack. Note strap orientation for reinstallation.
   Torque spec

   Tank Strap Bolts35 Nm (26 lb-ft)
9. 9

   Remove front fuel tank strap
   Remove the front fuel tank strap bolt on the driver side frame rail using 15mm socket. With both straps released, carefully lower the transmission jack slowly while guiding the tank down. Watch for any remaining connections or wiring that may still be attached. An assistant is helpful for this step.
   ⚠️Tank weighs 150-200 lbs even when mostly empty. Lower very slowly and maintain control at all times. Keep hands and body clear of potential pinch points.
   Torque spec

   Tank Strap Bolts35 Nm (26 lb-ft)
10. 10

    Lower and remove fuel tank
    Continue lowering jack until tank is on ground or low enough to slide out from under vehicle. Roll jack and tank out from under vehicle. If tank still contains significant fuel, drain remaining fuel through filler neck or by removing fuel pump module and draining into approved containers.
    ⚠Dispose of drained fuel properly at hazardous waste facility. Do not pour down drains or onto ground.
11. 11

    Inspect and clean mounting area
    With tank removed, inspect fuel tank straps, frame mounting points, and shield hardware for corrosion or damage. Wire brush frame rail mounting surfaces clean. Inspect all fuel lines, EVAP lines, and filler neck for damage or corrosion. Replace any damaged components before installing new or refurbished tank.
12. 12

    Prepare new tank for installation
    If installing new fuel pump module or sender, install now while tank is accessible. Transfer any necessary components from old tank to new tank (heat shields, mounting brackets). Install new O-rings on all fuel line fittings - do not reuse old O-rings. Lubricate new O-rings lightly with clean engine oil.
    ⚠Always use new O-rings on fuel line fittings. Old O-rings can leak and cause fire hazard. This is a critical safety component.
13. 13

    Position and raise tank into place
    Place tank on transmission jack and position under vehicle. Carefully raise tank into position, aligning mounting strap locations with frame rail brackets. An assistant should guide lines and connectors through their routing paths to prevent pinching or kinking. Raise until tank is in final position but straps not yet installed.
14. 14

    Install fuel tank straps
    Swing front tank strap up and over tank, align with frame mounting hole. Start bolt by hand and tighten to specified torque. Repeat for rear strap. Ensure straps are not twisted and are positioned correctly over tank support pads. Torque both strap bolts to specification.
    Torque spec

    Tank Strap Bolts35 Nm (26 lb-ft)
15. 15

    Reconnect all lines and electrical connections
    Reconnect fuel supply and return lines - push firmly until they click into place and tug to verify lock. Reconnect EVAP and vent lines. Reconnect fuel pump module electrical connector and verify locking tab engages. Slide filler neck hose onto tank inlet pipe and position clamp, then tighten clamp to specification. Reconnect fuel pump driver module connector on frame rail.
    ⚠Ensure all fuel line connections are fully seated and locked. Pull on each line to verify connection before proceeding.
    Torque spec

    Filler Neck Clamp4 Nm (3 lb-ft)
16. 16

    Reinstall fuel tank shield
    Position fuel tank shield/skid plate and install all mounting screws. Torque screws to specification in a cross-pattern to ensure even seating.
    Torque spec

    Cover Screws14 Nm (10 lb-ft)

Reassembly

1. Reconnect negative battery cable to battery terminal and tighten securely.
2. Before adding fuel, turn ignition key to ON position (do not start) for 5 seconds, then OFF. Repeat 3-4 times to prime fuel system and build pressure.
3. Inspect all fuel line connections, filler neck, and tank seams for any signs of leakage.
4. Add 2-3 gallons of fresh fuel to tank and recheck all connections for leaks.
5. Lower vehicle from jack stands and remove stands.
6. Start engine and let idle for several minutes while continuing to inspect for fuel leaks.
7. If any leaks are detected, shut off engine immediately, relieve pressure, and correct the leak before operating vehicle.

Verification

• With engine running, inspect entire fuel system from tank to engine bay for any fuel leaks or seepage.
• Check fuel tank straps for proper torque and that tank is secure with no movement.
• Verify fuel gauge reads correctly on instrument cluster.
• Check that all EVAP system connections are secure with no vacuum leaks (check engine light should not illuminate for EVAP codes).
• Test drive vehicle and verify normal fuel system operation with no fuel smell in cabin or visible leaks.
• After test drive, perform final inspection under vehicle for any signs of fuel leakage, paying special attention to fuel line connections and tank seams.
• Monitor vehicle for next several days for any fuel odor or check engine lights related to fuel system.

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