This procedure replaces the fuel pump module assembly located inside the fuel tank on 2015-2020 Ford F-150 5.0L V8 models, requiring fuel tank access and depressurization of the fuel system.

Warnings

Tools required

Parts

• Fuel pump module assembly × 1 — Motorcraft PFS-518 or equivalent
• Fuel pump lock ring seal/O-ring × 1 — Use OEM specification
• Fuel line O-rings × 2 — Use OEM specification

Preparation

1. Park vehicle outdoors on level ground away from all ignition sources. Ensure area is well-ventilated with no open flames, sparks, or hot equipment within 50 feet
2. Place fire extinguisher within immediate reach of work area
3. If fuel level is above 1/4 tank, use approved hand siphon pump to transfer fuel to approved gasoline storage container
4. Disconnect battery negative terminal and wait minimum 10 minutes before proceeding
5. Remove fuel filler cap to relieve any tank pressure
6. Chock front wheels securely to prevent vehicle movement

Procedure

1. 1

   Depressurize fuel system
   Locate the fuel pump fuse or relay in the engine compartment fuse box (refer to fuse diagram on box lid - typically 20A fuse in position F27 or relay R3). Remove the fuel pump fuse or relay. Attempt to start the engine and let it run until it stalls from fuel starvation. Attempt to restart 2-3 times to ensure fuel rail is depressurized. Turn ignition to OFF position and remove key. Wait 5 minutes before proceeding to next step.
   ⚠️Do not skip this step. Pressurized fuel lines will spray gasoline when disconnected, creating immediate fire hazard and risk of severe burns.
2. 2

   Raise and support vehicle
   Safely raise the rear of the vehicle using a floor jack at the rear axle differential housing. Support vehicle on jack stands rated for vehicle weight, positioned under the frame rails behind the cab. Lower vehicle onto jack stands and verify stability before working underneath. Do not rely solely on hydraulic jack.
   ⚠Vehicle must be securely supported on jack stands. Never work under a vehicle supported only by a hydraulic jack.
3. 3

   Access fuel pump module
   From inside the truck bed, locate the fuel pump access cover on the passenger side of the bed floor. If equipped with a plastic bed liner, remove or fold back to expose the access panel. The access cover is a rectangular plastic panel secured by Phillips screws. Remove the screws using appropriate driver and carefully lift the access panel to expose the fuel pump module assembly.
   Torque spec

   Access Cover Screws5 Nm (4 lb-ft)
4. 4

   Disconnect fuel pump electrical connector
   Locate the large electrical connector on top of the fuel pump module. Press the connector locking tab and pull connector straight up to disconnect. Do not pull on wires. Clean any dirt or debris from around the pump module top using a dry shop towel to prevent contamination from entering the fuel tank.
   ⚠Keep all dirt and debris away from fuel tank opening. Even small particles can damage the new fuel pump or clog fuel injectors.
5. 5

   Disconnect fuel supply and return lines
   Identify the fuel supply line (larger diameter, typically 3/8 inch) and return/vapor lines connected to the pump module top. Use appropriate size fuel line disconnect tools to release the quick-connect fittings. Push the disconnect tool onto the line, then pull the line straight off. Have shop towels ready to catch residual fuel spillage. Cap or plug open lines immediately to prevent contamination.
   ⚠️Expect fuel spillage even after depressurization. Keep towels and catch pan ready. Dispose of fuel-soaked towels in approved metal container immediately.
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 and turns counterclockwise to remove. Using the lock ring tool, carefully tap counterclockwise with a dead-blow hammer or use a breaker bar (depending on tool type) to loosen the lock ring. Once loose, unscrew completely by hand and remove the lock ring. Note the orientation of any alignment marks.
   ⚠️Use only non-sparking tools. Any spark near fuel tank opening can cause explosion. Brass or plastic tools preferred.
   ⚠Lock ring is under slight spring tension. Control removal to prevent dropping into tank.
   Torque spec

   Fuel Pump Lock Ring85 Nm (63 lb-ft)
7. 7

   Remove fuel pump module assembly
   Carefully lift the fuel pump module straight up and out of the fuel tank. The module includes a long fuel level sender arm that must be tilted at an angle to clear the tank opening. Tilt the module approximately 45 degrees as you lift to avoid bending the sender arm. Once clear, allow residual fuel to drain back into tank. Place the old module in an approved fuel-safe container for disposal. Inspect the tank opening and O-ring sealing surface for debris or damage.
   ⚠Fuel level sender arm is fragile and easily bent. Tilt module slowly and carefully during removal to prevent damage to tank opening or sender.
8. 8

   Prepare new fuel pump module
   Remove the new fuel pump module from packaging. Verify all components are present including new O-ring seal. Install the new O-ring seal onto the fuel pump module flange, ensuring it seats properly in the groove. Do not lubricate the O-ring with petroleum products; use clean gasoline only if lubrication is needed. Inspect the module for any shipping damage.
   ℹ️Verify the new module matches the old unit exactly, including electrical connector configuration and fuel line positions. Wrong module can cause fuel starvation or pump failure.
   Torque spec

   Fuel Line Fittings25 Nm (18 lb-ft)
9. 9

   Install new fuel pump module
   Carefully lower the new fuel pump module into the fuel tank opening at an angle to clear the fuel level sender arm (approximately 45 degrees). As the module enters the tank, straighten it to vertical position. Align any orientation marks or tabs on the module with corresponding marks on the tank flange. Press the module fully down until it seats against the O-ring seal. Ensure the module sits flat and even against the tank surface.
   ⚠Do not force the module. If resistance is felt, check for sender arm interference or misalignment. Forcing can bend components or damage O-ring seal.
10. 10

    Install and torque lock ring
    Place the fuel pump lock ring over the module, aligning the tabs. Thread the lock ring clockwise by hand until snug. Using the fuel pump lock ring tool and torque wrench, tighten the lock ring to specification in a clockwise direction. Verify the module does not rotate during tightening and that the lock ring is fully seated.
    ⚠Over-tightening can crack the module flange or tank. Under-tightening will cause fuel leaks. Use calibrated torque wrench.
    Torque spec

    Fuel Pump Lock Ring85 Nm (63 lb-ft)
11. 11

    Reconnect fuel lines
    Install new O-rings onto the fuel line fittings if supplied with pump module or purchased separately. Push each fuel line (supply, return, and vapor if equipped) onto the corresponding module fitting until you hear or feel a distinct click indicating the quick-connect has locked. Gently pull on each line to verify secure connection. Wipe away any fuel residue with shop towels.
    Torque spec

    Fuel Line Fittings25 Nm (18 lb-ft)
12. 12

    Reconnect electrical connector and test system
    Connect the fuel pump electrical connector to the module, ensuring it clicks into place. Clean the access panel area of any fuel residue. Reinstall the fuel pump fuse or relay that was removed in Step 1. Without starting the engine, turn the ignition key to ON position (not START) for 5 seconds, then OFF. Repeat this 3-4 times to prime the fuel system and pressurize the lines. Carefully inspect all connections at the fuel pump module for any fuel leaks. Look for drips or wetness around the lock ring seal and fuel line connections.
    ⚠️If any fuel leaks are detected, immediately turn ignition OFF, relieve fuel pressure, and correct the leak before proceeding. Do not attempt to start engine with active fuel leak.
13. 13

    Reinstall access cover and lower vehicle
    Once leak check is complete and no leaks are found, reinstall the fuel pump access cover panel and secure with screws to specification. Reposition bed liner if removed. Carefully raise vehicle slightly with floor jack, remove jack stands, and lower vehicle completely to ground. Reconnect battery negative terminal.
    Torque spec

    Access Cover Screws5 Nm (4 lb-ft)

Reassembly

1. Ensure all fuel line connections are secure and clicked into place before pressurizing system
2. Always replace fuel line O-rings when disconnecting fuel lines - reusing old O-rings will cause leaks
3. Access cover must be reinstalled to prevent fuel vapors from entering vehicle cab

Verification

• With vehicle in well-ventilated area and fire extinguisher ready, start the engine and verify it runs smoothly without stumbling or fuel starvation symptoms
• Check fuel pressure is within specification (40-60 psi for this engine) using fuel pressure gauge if available
• With engine running, visually inspect the fuel pump module area (access cover removed) for any fuel leaks around lock ring and line connections
• Monitor fuel gauge operation to verify fuel level sender is functioning correctly
• After test drive, perform final leak inspection of all fuel connections while engine is at operating temperature
• Verify no fuel odor is present in vehicle cab or truck bed area, indicating proper seal of access cover

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