This procedure replaces the fuel pump module in a 2015-2020 Ford F-150 with the 5.0L Coyote V8 engine by accessing the pump through the in-bed service cover.

Warnings

Tools required

Parts

• Fuel pump module assembly × 1 — Motorcraft PFS-487 or equivalent for 5.0L
• Fuel pump module seal/O-ring × 1 — Usually included with pump module
• Fuel line O-rings × 1 — Replace all disconnected line O-rings

Preparation

1. Park vehicle on level ground and engage parking brake. Ensure adequate ventilation in work area.
2. Place fire extinguisher within immediate reach of work area.
3. Turn ignition off and remove key. Verify all electrical accessories are off.
4. Open driver door and leave open to prevent lockout and maintain interior light access.
5. Disconnect negative battery terminal using 10mm wrench. Secure cable away from terminal. Wait minimum 2 minutes for module shutdown.
6. Remove rear seat bottom cushion by pulling firmly upward on front edge until clips release (2015-2020 models have retained clips).
7. If tank is more than 1/4 full, plan for fuel spillage containment. Have minimum 5 gallons of absorbent material or drain pan ready.
8. Locate fuel pump access cover on driver side of rear seat floor pan (approximately 18 inches forward of rear wall).

Procedure

1. 1

   Relieve fuel system pressure
   With battery disconnected, fuel pressure will gradually decrease but residual pressure remains. Locate the fuel rail Schrader valve on the driver side fuel rail. Place shop towels around valve. Using a small screwdriver or Schrader valve tool, slowly depress the valve core to release pressure. Expect fuel spray initially. Continue until no pressure is detected. On 2018+ models, the Schrader valve may be capped with a green cap. This step is critical even with battery disconnected.
   ⚠️Fuel will spray from the Schrader valve under high pressure. Keep face and ignition sources away. Use adequate towels to contain spray.
2. 2

   Remove fuel pump access cover
   Remove the sound deadening material or carpet covering the access panel if present. Locate the 8-10 Phillips head screws securing the plastic access cover. Remove all screws and carefully lift the access cover. The cover may have a seal; inspect and retain if reusable. You will now see the top of the fuel pump module lock ring and fuel line connections.
3. 3

   Disconnect electrical connector
   Locate the fuel pump module electrical connector on top of the pump assembly. Press the connector release tab (gray or blue tab on side of connector) and pull the connector straight up and away from the module. Inspect connector terminals for corrosion or damage. Set connector aside in a clean area where it will not contact fuel.
   ⚠Do not pull on wires. Use only the connector body to remove. Damaged pins will prevent pump operation.
4. 4

   Disconnect fuel supply line
   The fuel supply line connects to the top of the pump module with a spring-lock quick-connect fitting (typically 5/8 inch). Clean around the connection to prevent dirt entry. Using the appropriate spring-lock disconnect tool, insert the tool into the fitting and push toward the module while pulling the line away. You may need to twist slightly while pulling. Expect residual fuel spillage (1-2 cups). Plug the line with a clean rag or cap to prevent contamination.
   ⚠Residual fuel under pressure may spray when disconnecting. Keep face away and have towels ready to catch spillage.
5. 5

   Disconnect fuel return line
   The return line is a smaller quick-connect fitting (typically 3/8 inch) also on top of the module. Use the smaller spring-lock disconnect tool. Follow the same procedure: clean area, insert tool, push in and pull line out. Expect minimal fuel spillage from this line. Cap or plug the line opening.
6. 6

   Remove fuel pump lock ring
   Using the fuel pump lock ring tool (Ford 310-069 or equivalent), engage the tool teeth into the lock ring notches. The lock ring turns counterclockwise to remove. Apply steady force; the ring may be tight due to corrosion or previous installation. Once loosened, unthread the lock ring completely by hand and remove. Inspect lock ring threads on both ring and tank for damage or corrosion. Clean threads with a wire brush or thread chaser if needed.
   ⚠Do not use hammer and punch to remove lock ring. This can create sparks near fuel vapors and damage the ring or tank threads.
7. 7

   Remove fuel pump module assembly
   Carefully lift the fuel pump module assembly straight up out of the tank opening. The module is approximately 10-12 inches tall with a float arm and fuel level sender attached. Tilt the module slightly to angle the float arm and sender through the opening. Fuel will drain from the module back into tank; have towels ready under the opening. Once clear of the tank, place module in drain pan. DO NOT drop or damage the float arm or fuel level sender.
   ⚠️Fuel vapors are concentrated at the tank opening. Ensure adequate ventilation. Do not create sparks or use electrical devices near the opening.
   ⚠The fuel level sender is fragile. Bending the float arm will cause inaccurate fuel gauge readings.
8. 8

   Inspect and clean tank opening
   With the module removed, inspect the inside of the tank opening for debris, rust, or contamination. Use a flashlight to look into the tank. Check the O-ring sealing surface on the tank for scratches, corrosion, or damage. Clean the sealing surface thoroughly with a clean lint-free cloth. Remove the old O-ring seal from the tank and discard. Do not allow debris to fall into the tank.
   ℹ️If significant rust, debris, or water contamination is visible in the tank, the tank should be removed and cleaned or replaced before installing the new pump.
9. 9

   Prepare new fuel pump module
   Remove the new fuel pump module from packaging. Verify the module matches the old unit (same connector type, mounting pattern, and configuration). Install the new O-ring seal onto the module (or tank, depending on design). Lightly lubricate the O-ring with clean fuel or petroleum jelly to ease installation. Verify the float arm moves freely and is properly positioned. Check that all electrical connections on the module are clean and undamaged.
   ⚠Do not use silicone-based lubricants on fuel system O-rings. Use only petroleum jelly or clean gasoline.
10. 10

    Install new fuel pump module
    Carefully lower the new fuel pump module into the tank opening. Align the module orientation marks or tabs with the corresponding marks on the tank (usually an arrow or notch indicating forward direction). Tilt the float arm and sender to pass through the opening without bending. Ensure the O-ring seats properly in the tank groove. Press the module down fully until it contacts the O-ring and sits flush with the tank surface. Verify alignment marks are correct before proceeding.
    ⚠Incorrect module orientation will prevent proper fuel pickup and cause fuel starvation. Verify alignment marks match before installing lock ring.
11. 11

    Install and torque lock ring
    Thread the lock ring onto the tank by hand, turning clockwise. Ensure the ring threads smoothly without cross-threading. Hand-tighten until snug. Using the lock ring tool and torque wrench, tighten the lock ring to 81 Nm (60 lb-ft) in a clockwise direction. Apply torque smoothly; do not impact or shock load. Verify the module does not rotate during tightening. Check that the O-ring remains properly seated.
12. 12

    Reconnect fuel lines
    Inspect the O-rings inside both the supply and return line quick-connect fittings. Replace O-rings if damaged, flattened, or hardened. Push the supply line (larger, 5/8 inch) straight onto the module fitting until you hear and feel a distinct click. Tug on the line to verify it is locked. Repeat with the return line (smaller, 3/8 inch). Both lines must click and lock securely.
    ⚠Improperly connected quick-connect fittings will leak under pressure, creating fire hazard and fuel smell. Verify positive locking engagement.
13. 13

    Reconnect electrical connector
    Align the electrical connector with the module terminal and push straight down until you hear a click. The connector lock tab should engage fully. Tug gently on the connector to verify it is locked. Inspect the connection to ensure no pins are bent or misaligned.
    ℹ️A loose electrical connection will prevent pump operation and may cause no-start condition or intermittent fuel delivery.
14. 14

    Reinstall access cover
    Clean the access cover and surrounding floor pan area. Position the access cover over the opening, aligning screw holes. Install all screws and tighten to 5.0 Nm (4.0 lb-ft) in a cross-pattern to ensure even sealing. Replace sound deadening material or carpet if removed.
15. 15

    Reconnect battery and prime fuel system
    Reconnect the negative battery terminal and tighten securely. Turn the ignition to ON position (do not start engine) for 5 seconds, then OFF. Repeat this cycle 3-4 times to allow the fuel pump to prime the system and build pressure. Listen for the fuel pump running during the ON cycle (2-3 second hum from rear of vehicle). After priming, check all fuel line connections at the module for leaks before starting the engine.
    ⚠️Inspect for fuel leaks thoroughly before starting engine. Any leak at the module or lines creates immediate fire hazard.

Reassembly

1. Reinstall rear seat cushion by aligning clips and pressing firmly until all clips engage.
2. Verify all tools and parts are removed from vehicle interior.
3. Properly dispose of old fuel pump module and contaminated shop towels according to local hazardous waste regulations.

Verification

• With engine off and ignition on, verify fuel pump runs for 2-3 seconds (audible hum from rear).
• Start engine and let idle for 2 minutes. Monitor for rough idle, hesitation, or stalling indicating fuel delivery issues.
• Check fuel gauge operation. Gauge should accurately reflect tank fuel level within 1-2 minutes of ignition on.
• Inspect access cover area and all fuel line connections for fuel odor or visible leaks.
• Perform a test drive including acceleration and fuel tank levels from full to 1/4 tank to verify pump operation under all conditions.
• Re-check all connections after test drive. Any fuel odor indicates a leak that must be corrected immediately.
• Verify no diagnostic trouble codes (DTCs) related to fuel system using OBD-II scanner.

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