This procedure replaces the fuel tank mounting straps on a 2011-2014 Ford F-150 3.5L EcoBoost 4WD, requiring fuel system depressurization, tank lowering, and proper torque specifications to ensure safe fuel system operation.

Warnings

Tools required

Parts

• Fuel tank strap set (2 straps) × 1 — Ford BC3Z-9054-B or equivalent
• Fuel line O-ring kit × 1 — Use OEM specification
• Fuel tank shield hardware (if corroded) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface in well-ventilated area away from ignition sources. Ensure Class B fire extinguisher is accessible.
2. Disconnect negative battery cable and isolate it from battery terminal to prevent electrical sparks.
3. Remove fuel pump fuse (location: fuse box under hood, check owner's manual for specific location) and start engine. Allow engine to run until it stalls to depressurize fuel system.
4. Attempt to start engine 2-3 more times to ensure fuel pressure is fully relieved.
5. If fuel level is above 1/4 tank, siphon or drain fuel into approved gasoline containers using approved fuel transfer pump. Do NOT use mouth siphoning.
6. Raise vehicle on lift or use floor jack with jack stands rated for vehicle weight. Vehicle must be securely supported at all four corners.
7. Place wheel chocks at front wheels if working on lift.
8. Remove fuel tank skid plate/shield if equipped (multiple bolts/screws around perimeter).

Procedure

1. 1

   Access fuel tank connections
   Locate the fuel filler neck hose at the rear driver's side of the tank. Using appropriate size hose clamp pliers or screwdriver, loosen the hose clamp securing the filler neck to the tank. Slide clamp back on hose away from tank connection point. Do not remove hose yet.
2. 2

   Disconnect EVAP and vent lines
   Locate the EVAP vent line and vapor lines on top of the fuel tank. These are quick-disconnect plastic fittings. Using fuel line disconnect tools of appropriate size (typically 3/8 inch and 1/4 inch), press the tool into the fitting while pulling the line away from the tank nipple. Mark or photograph line positions for reassembly reference.
   ⚠Do not use screwdrivers or pliers on plastic quick-connect fittings as they will damage the locking mechanism and cause fuel leaks.
3. 3

   Disconnect fuel supply and return lines
   Locate the fuel supply line (larger diameter, typically 3/8 inch) and return line at the front of the tank. Place a drain pan beneath the connections as residual fuel will drain. Using the appropriate size fuel line disconnect tool, press the release tabs while pulling the line straight off the tank fitting. Cap or plug the open lines to prevent fuel spillage and contamination.
   ⚠Expect fuel spillage. Have absorbent materials ready and ensure drain pan is positioned to catch fuel.
   Torque spec

   Fuel Line Fittings25 Nm (18 lb-ft)
4. 4

   Disconnect electrical connectors
   Locate the fuel pump module electrical connector on top of the tank (accessible from above, may need to move heat shield). Press the release tab and disconnect the electrical connector from the fuel pump module. On some models, there may be a fuel tank pressure sensor connector as well - disconnect this by pressing the release tab.
5. 5

   Position support jack
   Position a hydraulic transmission jack or fuel tank jack under the center of the fuel tank. Raise the jack until it just contacts the tank bottom with slight pressure to support the weight. Use a wide wooden block between jack and tank to distribute load and prevent tank damage. Ensure the tank is stable and balanced on the jack before proceeding.
   ⚠️The jack MUST adequately support the full weight of the tank. Do not proceed if the tank is unstable or improperly balanced.
6. 6

   Remove fuel tank strap mounting bolts
   Locate the two fuel tank straps that run under the tank from front to rear. Each strap has a mounting bolt at the rear end that threads into a frame bracket. Using a 19mm socket and ratchet, remove both strap mounting bolts completely. Support the straps as the second bolt is removed to prevent them from swinging down forcefully.
   ⚠Straps are under tension and will release suddenly when the second bolt is removed. Maintain control of straps.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
7. 7

   Lower fuel tank partially
   Slowly lower the transmission jack approximately 6 inches. Monitor all remaining connections to ensure nothing is still attached. The tank should lower freely. If resistance is felt, stop and identify any remaining connections. Once partially lowered, remove the fuel filler neck hose completely by pulling it off the tank nipple.
8. 8

   Remove fuel tank straps
   With the tank lowered, the straps will be slack. Remove both fuel tank straps completely from the vehicle by sliding them out from their mounting positions. Inspect the strap mounting points on the frame for corrosion or damage. Wire brush any rust from mounting surfaces.
9. 9

   Inspect and prepare new straps
   Inspect the tank for damage where the old straps contacted it. Check for any signs of abrasion, cracks, or deformation. Clean the strap contact areas on the tank. Compare new straps to old straps to verify correct replacement parts. Apply a thin coat of anti-seize compound to the mounting bolt threads (do not apply to bolt heads or seating surfaces).
10. 10

    Install new fuel tank straps
    Position the new fuel tank straps over the tank in their mounting locations, routing them from front to rear on each side. Ensure the straps are properly seated in the tank indentations and not twisted. Raise the transmission jack slowly to lift the tank into position, aligning the strap ends with the frame mounting holes.
11. 11

    Secure strap mounting bolts
    Thread both strap mounting bolts into the frame brackets by hand to ensure proper thread engagement. Once both bolts are hand-tight, use a torque wrench and 19mm socket to tighten both mounting bolts to specification in an alternating pattern (partially tighten one, then the other, then return to final torque). This ensures even strap tension.
    ⚠Proper torque is critical. Over-tightening can damage the tank; under-tightening can allow the tank to shift and damage fuel lines.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
12. 12

    Reconnect filler neck and hoses
    Raise the tank to its final position if not already there. Slide the fuel filler neck hose onto the tank nipple, ensuring it is fully seated (approximately 2 inches of engagement). Position the hose clamp over the connection point and tighten to specification using a torque screwdriver or carefully with a nut driver.
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)
13. 13

    Reconnect fuel lines with new O-rings
    Install new O-rings on all fuel line fittings per the O-ring kit instructions. Lubricate the new O-rings with clean engine oil. Push each fuel line straight onto its corresponding tank fitting until you hear and feel a positive click. Gently pull on each line to verify it is locked in place. Reconnect fuel supply, return, EVAP, and vent lines to their marked positions.
    ⚠️Failure to use new O-rings or verify positive connection can result in fuel leaks and fire hazard.
    Torque spec

    Fuel Line Fittings25 Nm (18 lb-ft)
14. 14

    Reconnect electrical and reinstall shields
    Reconnect the fuel pump module electrical connector by pushing it onto the module until it clicks into place. Verify the connector lock is engaged. Reconnect any fuel tank pressure sensor connectors. Reinstall the fuel tank skid plate/shield if equipped, torquing fasteners to specification.
    Torque spec

    Cover Screws12 Nm (9 lb-ft)
15. 15

    Perform leak check
    Carefully lower the transmission jack and remove it from under the vehicle. Reconnect the negative battery cable. Reinstall the fuel pump fuse. Turn the ignition key to the ON position (do not start engine) for 5 seconds, then OFF. Repeat this cycle 3-4 times to pressurize the fuel system. Inspect all fuel line connections, filler neck, and tank seams for any signs of fuel leakage using a flashlight. Check for fuel odor.
    ⚠️If ANY fuel leakage is detected, immediately turn off ignition, relieve fuel pressure, and repair the leak before proceeding. Do not start the engine.

Reassembly

1. Ensure all fuel line quick-connect fittings are fully engaged and locked with no gaps visible between the fitting and the nipple.
2. Verify fuel tank is sitting evenly in the straps with no interference with exhaust, driveshaft, or suspension components.
3. Double-check that all electrical connectors are fully seated and locked.
4. Confirm fuel tank skid plate/shield is reinstalled and properly secured if equipped.
5. Remove all tools, drain pans, and materials from under the vehicle before lowering.

Verification

• With vehicle still raised, visually inspect all fuel connections and the tank itself for any signs of fuel leakage or wetness.
• Lower vehicle to ground. Start the engine and allow it to idle for 2-3 minutes while monitoring for fuel odors or drips.
• Turn off engine and perform a final inspection underneath the vehicle with a flashlight, checking all connection points and along the fuel lines.
• Test drive the vehicle and listen for any unusual noises from the fuel tank area. Check for proper fuel gauge operation.
• After test drive, perform a final leak inspection of all fuel system connections with the engine off and the system pressurized (key ON, engine OFF).
• Monitor the area under the vehicle for 24 hours for any delayed fuel seepage, especially if new O-rings were compressed during installation.

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