This procedure covers removal and replacement of the fuel level sensor on a 2015-2020 Ford F-150 with 5.0L V8 engine, requiring fuel tank lowering for access to the sensor module.

Warnings

Tools required

Parts

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

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable and wait 5 minutes to allow fuel pump to depressurize
3. Relieve residual fuel system pressure by removing fuel pump relay (located in engine bay fuse box, position F1.32) and attempting to start engine until it stalls
4. Raise and safely support rear of vehicle on jack stands at frame rails
5. Place drain pans under fuel tank area to catch spillage
6. If fuel level is above half tank, siphon or drain fuel into approved fuel-safe containers

Procedure

1. 1

   Disconnect fuel filler neck
   Locate the fuel filler neck hose connection at the rear passenger side of the tank. Loosen the hose clamp using a flathead screwdriver or socket, then carefully slide the filler neck hose off the tank inlet. Be prepared for minor fuel spillage.
   Torque spec

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

   Disconnect EVAP and vent lines
   Locate the EVAP canister vent line and vapor line connections on top of the fuel tank. Press the quick-disconnect tabs and pull the lines free from the tank fittings. Cap or plug the lines to prevent contamination.
3. 3

   Disconnect fuel supply and return lines
   Using the appropriate fuel line disconnect tool, release the quick-connect fittings on the fuel supply line and return line at the front of the fuel tank. Push the tool onto the line, then pull the line free. Have shop towels ready to catch residual fuel. Note the orientation and routing of lines for reinstallation.
   ⚠Fuel will drain from lines when disconnected. Catch fuel in drain pan and dispose of properly.
4. 4

   Disconnect fuel pump electrical connector
   Locate the fuel pump module electrical connector on the top driver side of the fuel tank. Press the locking tab and disconnect the electrical connector. Secure the wiring harness out of the way to prevent damage during tank lowering.
5. 5

   Support and lower fuel tank
   Position transmission jack or fuel tank support device under the center of the fuel tank. Raise jack until it just contacts the tank to support weight. Remove the two fuel tank strap mounting bolts at the rear crossmember. Carefully pivot straps down and away. Slowly lower the jack, lowering the tank approximately 6-8 inches. Ensure all hoses and wiring are clear.
   ⚠️Tank may shift during lowering. Keep hands and body clear of pinch points. Lower tank slowly and steadily.
   Torque spec

   Mounting Bolts34 Nm (25 lb-ft)
6. 6

   Remove fuel pump module lock ring
   Clean debris from the top of the fuel tank around the fuel pump module access cover. Using the lock ring spanner tool, rotate the fuel pump module lock ring counterclockwise to release. Remove the lock ring completely.
   ⚠Do not use hammers or chisels that could create sparks near fuel tank.
7. 7

   Remove fuel pump module assembly
   Carefully lift the fuel pump module assembly out of the tank opening. Tilt the assembly at an angle to clear the fuel level sender float arm. Allow fuel to drain back into tank. Place the module on shop towels in a clean area, keeping it upright to prevent fuel spillage.
8. 8

   Remove fuel level sensor from module
   Locate the fuel level sensor attached to the side of the fuel pump module assembly. Disconnect the internal electrical connector from the sensor. Remove the sensor mounting clip or release tabs (design varies by year). Carefully slide the fuel level sensor and float arm assembly out of the module housing. Note the orientation of the float arm for correct installation.
9. 9

   Install new fuel level sensor
   Install the new fuel level sensor into the module housing in the same orientation as the original. Ensure the float arm moves freely through its full range without binding. Secure the sensor with the mounting clip or tabs. Connect the internal electrical connector to the sensor, ensuring it clicks into place.
10. 10

    Install fuel pump module assembly
    Inspect and replace the large O-ring seal on the fuel pump module if damaged or worn. Lubricate the O-ring with clean fuel. Carefully lower the fuel pump module assembly into the tank opening, tilting as needed to clear the float arm. Ensure the module seats fully against the tank and the O-ring is properly positioned.
11. 11

    Install lock ring
    Position the fuel pump module lock ring over the module and engage the threads. Using the lock ring spanner tool, rotate the lock ring clockwise until fully tightened. Ensure the lock ring is seated evenly around the entire circumference.
12. 12

    Raise and secure fuel tank
    Using the support jack, carefully raise the fuel tank back into position against the vehicle underbody. Ensure all hoses and wiring are routed correctly and not pinched. Swing the fuel tank straps back into position and install the mounting bolts. Torque the strap mounting bolts to specification.
    Torque spec

    Mounting Bolts34 Nm (25 lb-ft)
13. 13

    Reconnect fuel and EVAP lines
    Install new O-rings on all fuel line fittings. Connect the fuel supply and return lines to the tank, ensuring they click securely into place. Tug on each line to verify connection. Reconnect the EVAP vent line and vapor line. Connect the fuel pump electrical connector until it clicks.
14. 14

    Reconnect filler neck
    Slide the fuel filler neck hose onto the tank inlet, ensuring it is fully seated over the bead. Install and tighten the hose clamp to specification.
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)

Reassembly

1. Reinstall fuel pump relay in engine bay fuse box
2. Reconnect negative battery cable
3. Lower vehicle from jack stands
4. Add fuel if tank was drained below minimum operating level (approximately 2 gallons minimum)

Verification

• Turn ignition to ON position (do not start) and listen for fuel pump to prime for 2-3 seconds. Repeat key cycle 3-4 times to pressurize system
• Inspect all fuel line connections and tank area for any fuel leaks while system is pressurized
• Start engine and verify it runs normally without fuel delivery issues
• Check instrument cluster fuel gauge and verify it shows accurate fuel level reading
• Monitor fuel gauge through various fuel levels over next few days to confirm proper sensor operation throughout range
• Clear any diagnostic trouble codes related to fuel level sensor using scan tool if present

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