This procedure covers the removal and replacement of the fuel tank support straps on a 2015-2020 Ford F-150 with 3.5L EcoBoost engine, including safe fuel system depressurization and disconnection.

Warnings

Tools required

Parts

• Fuel tank strap kit (set of 2) × 1 — Ford OEM BC3Z-9054-A or equivalent
• Fuel line O-rings × 4 — Use OEM specification
• Strap mounting bolts (if corroded) × 4 — M12 x 1.75 x 90mm

Preparation

1. Park vehicle on a level, paved surface in a well-ventilated area away from ignition sources
2. Ensure fuel tank is less than 1/4 full. If necessary, use an approved fuel transfer pump to drain excess fuel into approved containers
3. Disconnect negative battery cable and wait 2 minutes for airbag system to discharge
4. Place Class B fire extinguisher within immediate reach of work area
5. Chock front wheels and engage parking brake
6. Raise rear of vehicle to comfortable working height using floor jack and support on jack stands rated for vehicle weight at frame rails behind rear axle
7. Place transmission jack or fuel tank support fixture under center of fuel tank but do not raise
8. Allow exhaust system to cool completely if vehicle was recently driven (minimum 2 hours)
9. Spray all fuel line fittings and strap bolts with penetrating oil and allow to soak for 15-30 minutes

Procedure

1. 1

   Relieve fuel system pressure
   Remove the fuel pump relay from the engine compartment fuse box (relay location shown in owner's manual, typically labeled 'Fuel Pump' in position F16). Attempt to start the engine and let it run until it stalls. Attempt to start 2-3 more times to ensure pressure is fully relieved. Turn ignition to OFF position and remove key.
   ⚠Small amounts of fuel may still be present in lines even after depressurization. Have shop towels ready.
2. 2

   Disconnect fuel filler neck and vent lines
   Locate the fuel filler neck on the driver side behind rear wheel. Using appropriate hose clamp pliers or screwdriver, loosen the hose clamp securing the filler neck to the fuel tank inlet. Slide clamp back on hose. Disconnect the EVAP vent line from the top of the filler neck using a spring lock disconnect tool. Twist and pull the filler neck away from tank inlet. Allow any residual fuel to drain into drip pan.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
3. 3

   Disconnect fuel supply and return lines
   Locate the fuel line connections at the front of the fuel tank. The 3.5L EcoBoost uses spring-lock style quick-connect fittings. Clean the connection area with a shop towel. Using the appropriate size fuel line disconnect tool, insert it into the spring lock fitting and push toward the tank while pulling the line away. Disconnect both the supply line (larger diameter, typically 3/8 inch) and return line (smaller diameter, typically 5/16 inch). Cap open lines with approved fuel line plugs or wrap with plastic and secure with zip ties to prevent contamination.
   ⚠Expect fuel spillage from lines. Position drip pan to catch fuel. Use fuel-resistant gloves.
4. 4

   Disconnect electrical connectors
   Locate the fuel pump module electrical connector on top of the fuel tank (accessed from below). Press the connector release tab and pull connector straight off. If equipped, disconnect the fuel tank pressure sensor connector using the same method. On EcoBoost models, there may be an additional EVAP canister connector near the driver side strap - disconnect if present. Secure all connectors up and out of the way with mechanics wire or zip ties.
   ℹ️Take a photo of connector positions before removal for reference during reassembly.
5. 5

   Disconnect EVAP canister and lines
   Locate the EVAP canister mounted to the driver side fuel tank strap or frame rail. Disconnect any remaining EVAP lines using quick-disconnect tools. Remove the canister mounting bracket bolts and lower the canister with lines attached, securing it out of the way. Do not allow the canister to hang by its lines.
   Torque spec

   Bracket Bolts23 Nm (17 lb-ft)
6. 6

   Support fuel tank with transmission jack
   Position the transmission jack or fuel tank support fixture directly under the center of the fuel tank. Raise the jack until it just makes contact with the tank bottom - there should be light pressure but the straps should still be supporting the weight. Ensure the tank is balanced and stable on the jack before proceeding. Use wide wooden blocks or a fuel tank adapter on the jack saddle to distribute load and prevent tank damage.
   ⚠️The tank must be securely supported before loosening straps. Verify stability by gently pushing on the tank from multiple sides.
7. 7

   Remove fuel tank strap mounting bolts
   Locate the two fuel tank straps running across the bottom of the tank from driver to passenger side. Each strap is secured by a bolt at each end (4 bolts total) threading into frame-mounted brackets. Using a socket and ratchet, remove the forward mounting bolt from the passenger side strap, then the rear mounting bolt. Support the strap as you remove the second bolt. Repeat for the driver side strap. The straps will hang down once bolts are removed. If bolts are heavily corroded, apply additional penetrating oil and use a wire brush to clean threads.
   ⚠Straps are under tension and may spring down when final bolt is removed. Keep hands clear of pinch points.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
8. 8

   Lower fuel tank partially
   With straps removed and tank supported on jack, slowly and carefully lower the transmission jack approximately 6-8 inches. Work slowly and stop frequently to verify no hoses, lines, or wires are caught or under tension. If any resistance is felt, stop and identify the cause before continuing. The tank only needs to drop enough to access the top and remove the straps from underneath.
   ⚠️Never lower the tank rapidly or allow it to become unstable. Have an assistant help guide the tank if possible.
9. 9

   Remove old fuel tank straps
   Slide the old straps out from under the fuel tank. Inspect the strap mounting points on the frame for corrosion or damage. Clean mounting surfaces with a wire brush. Inspect the rubber isolators on the tank where straps contact - replace if torn, compressed, or deteriorated. Check frame brackets for cracks or damage.
   ℹ️Take photos of strap routing and orientation before complete removal for installation reference.
10. 10

    Install new fuel tank straps
    Position the new fuel tank straps under the tank in the same orientation as the originals. The straps should be centered on the tank with equal overhang on each side. Verify rubber isolators are properly seated between strap and tank. Apply anti-seize compound to the threads of the mounting bolts if operating in corrosive environment.
    ⚠Verify strap orientation - they may be marked 'front' or have different profiles. Installing backwards can cause interference.
11. 11

    Raise tank and align straps to mounting brackets
    Carefully raise the transmission jack to lift the fuel tank back into position. Align the holes in the strap ends with the mounting brackets on the frame. This may require minor adjustment of tank position - work slowly and have an assistant help align if possible. Once one bolt can be started by hand, install it finger-tight but do not fully tighten yet.
    ⚠Do not force bolt alignment. If bolts will not align easily, lower tank slightly and reposition.
12. 12

    Install and torque strap mounting bolts
    Install all four strap mounting bolts finger-tight first. Verify straps are properly centered and not twisted. Starting with the passenger side front bolt, torque to specification using a torque wrench. Follow with passenger side rear, then driver side front, then driver side rear in a cross-pattern. Recheck all four bolts to ensure proper torque after initial tightening.
    ⚠Over-tightening can distort tank or damage threads. Under-tightening can allow tank movement. Use calibrated torque wrench.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
13. 13

    Reconnect EVAP canister and lines
    Reinstall the EVAP canister to its mounting bracket and torque bracket bolts to specification. Reconnect all EVAP lines to the canister and fuel tank filler neck, ensuring quick-disconnect fittings click fully into place. Tug on each line to verify secure connection.
    Torque spec

    Bracket Bolts23 Nm (17 lb-ft)
14. 14

    Reconnect fuel lines with new O-rings
    Install new O-rings on the fuel supply and return line fittings - lubricate lightly with clean engine oil. Push each fuel line straight onto its tank fitting until you hear/feel a click indicating the spring lock has engaged. Pull on each line firmly to verify it is locked. For threaded fittings if equipped, torque to specification.
    ⚠Reusing old O-rings can cause fuel leaks. Always install new O-rings during fuel system reassembly.
    Torque spec

    Fuel Line Fittings25 Nm (18 lb-ft)
15. 15

    Reconnect electrical connectors and filler neck
    Reconnect the fuel pump module electrical connector, pressing firmly until it clicks. Reconnect tank pressure sensor and any other disconnected electrical connectors. Reinstall the fuel filler neck onto the tank inlet, sliding it fully onto the pipe. Position the hose clamp over the connection area and tighten securely.
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)
16. 16

    Final inspection and lower vehicle
    Perform a final visual inspection of all connections, ensuring no lines are kinked, pinched, or under tension. Verify all electrical connectors are fully seated. Remove the transmission jack. Lower the vehicle to the ground. Reconnect the negative battery cable. Reinstall the fuel pump relay in the fuse box.

Reassembly

1. Torque all fasteners to specified values using a calibrated torque wrench
2. Ensure all fuel line quick-disconnect fittings are fully engaged and locked
3. Verify all electrical connectors are fully seated with locking tabs engaged
4. Replace all O-rings on fuel connections - never reuse old O-rings
5. Do not over-torque hose clamps which can damage rubber components

Verification

• Turn ignition to ON position (without starting) for 10 seconds, then OFF. Repeat 3 times to pressurize fuel system
• Inspect all fuel line connections for leaks while system is pressurized - look for wetness or fuel smell
• Start the engine (may take extended cranking on first attempt as system reprimes). Let idle for 2 minutes
• While engine is running, inspect underneath vehicle with flashlight for any fuel drips from tank area
• Rev engine to 2000 RPM and verify no fuel leaks under increased pressure
• Take a short test drive and recheck all connections for leaks after vehicle returns
• Verify no fuel smell inside cabin with HVAC fan on high
• Check for diagnostic trouble codes related to fuel system or EVAP system
• Monitor fuel gauge operation to ensure sender is functioning properly

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