This procedure covers removal and replacement of the fuel level sensor (fuel pump module) in the fuel tank of a 2015-2020 Ford F-150 with 3.5L EcoBoost engine.

Warnings

Tools required

Parts

• Fuel level sensor/pump module × 1 — Use OEM specification
• Fuel pump module O-ring seal × 1 — Use OEM specification
• Fuel line O-rings × 2 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Disconnect negative battery cable and wait 5 minutes to allow fuel system to depressurize
3. If fuel tank is more than 1/4 full, siphon excess fuel into approved container
4. Raise rear of vehicle and secure on jack stands at frame rails
5. Remove spare tire if stored under bed

Procedure

1. 1

   Relieve fuel system pressure
   Remove the fuel pump relay (relay R10) from the central junction box under hood. Attempt to start engine and let it run until it stalls. Crank engine for 5 additional seconds to ensure pressure is fully relieved. Turn ignition off and reinstall relay.
2. 2

   Access fuel tank
   From under vehicle, locate the fuel tank shield/skid plate if equipped. Remove mounting bolts securing the shield and lower it. Identify the fuel pump module access area on top of tank.
3. 3

   Disconnect fuel lines
   Clean area around fuel line connections to prevent contamination. Using appropriate fuel line disconnect tools, disconnect the supply and return fuel lines from the pump module. Be prepared for residual fuel spillage. Plug lines with clean rags or caps to prevent contamination.
   ⚠Fuel will spill from lines. Have drain pan and towels ready.
   Torque spec

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

   Disconnect electrical connector
   Press the locking tab and disconnect the large electrical connector from the fuel pump module. Move wiring harness clear of work area.
5. 5

   Support fuel tank
   Position floor jack with wood block under center of fuel tank to support its weight. Raise jack slightly to take tension off tank straps.
6. 6

   Remove fuel tank straps
   Remove the two fuel tank strap mounting bolts. Carefully lower tank 6-8 inches to gain better access to pump module. Ensure fuel lines and electrical connector are not under tension.
   Torque spec

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

   Remove pump module lock ring
   Clean debris from around the fuel pump module lock ring. Using the fuel tank lock ring tool, rotate the lock ring counterclockwise until it releases. Remove lock ring completely and set aside.
8. 8

   Extract fuel pump module
   Carefully lift the fuel pump module out of the tank at an angle to avoid damaging the float arm. Tilt module to allow fuel to drain back into tank. Once clear, remove the old O-ring seal from the tank opening and discard.
   ⚠Module must be tilted and rotated carefully to clear tank opening without bending float arm.
9. 9

   Prepare new fuel level sensor module
   Remove new fuel pump module from packaging. Install new O-ring seal onto the module flange, ensuring it seats properly in the groove. Lubricate O-ring lightly with clean engine oil. Install new O-rings on fuel line fittings.
10. 10

    Install new pump module
    Carefully lower the new fuel pump module into the tank at an angle, rotating and tilting as needed to clear the opening without damaging the float arm or fuel level sensor. Ensure module is fully seated and alignment marks line up with tank opening.
11. 11

    Install lock ring
    Install the lock ring and rotate clockwise using the lock ring tool until it locks into position. Ensure ring is fully engaged and module is secure.
12. 12

    Reconnect fuel lines and electrical
    Reconnect fuel supply and return lines to module, ensuring they click into place securely. Tug gently to verify connection. Reconnect electrical connector until locking tab clicks.
    Torque spec

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

    Reinstall fuel tank
    Raise fuel tank into position using floor jack. Install tank straps and secure with mounting bolts. Torque bolts to specification. Remove jack support.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
14. 14

    Complete reassembly
    Reinstall fuel tank shield if equipped. Lower vehicle from jack stands. Reconnect negative battery cable.

Reassembly

1. Ensure all fuel line connections are secure with no leaks
2. Verify electrical connector is fully seated and locked
3. Tank straps must be torqued to specification to prevent movement
4. Double-check that no tools or parts were left under vehicle

Verification

• Turn ignition to ON position (do not start) for 5 seconds, then OFF. Repeat 3 times to prime fuel system
• Inspect all fuel line connections and pump module seal for leaks
• Start engine and verify it runs smoothly without fuel pressure issues
• Check instrument cluster fuel gauge reading - should reflect actual fuel level in tank
• Test drive vehicle and monitor fuel gauge operation through various fuel levels
• Scan for diagnostic trouble codes related to fuel level sensor or fuel system

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