Fuel Tank Strap

This procedure covers removal and replacement of the fuel tank support straps on a 2015-2020 Ford F-150 with 5.0L V8 engine, including fuel tank lowering and reinstallation.

Warnings

Tools required

Parts

• Fuel tank strap set (2 straps) × 1 — Use OEM specification
• Fuel line O-rings × 4 — Use OEM specification

Preparation

1. Park vehicle on level, firm surface and engage parking brake
2. Disconnect negative battery terminal and wait 10 minutes for system de-energization
3. Relieve fuel system pressure: Remove fuel pump fuse (fuse 27 in engine compartment fuse box), start engine and let it run until it stalls, then crank for 5 seconds to ensure pressure is relieved
4. If fuel tank is more than 1/4 full, use approved fuel transfer pump to remove fuel into approved storage containers
5. Raise vehicle on lift or jack and support securely on jack stands at manufacturer-specified lift points
6. Remove driver side rear wheel for improved access (not strictly required but recommended)
7. Allow exhaust system to cool completely if vehicle was recently driven (minimum 2 hours)
8. Position hydraulic transmission jack or fuel tank jack under center of fuel tank
9. Have fire extinguisher and spill cleanup materials readily accessible

Procedure

1. 1

   Disconnect fuel filler neck and vent lines
   Locate the fuel filler neck at the left rear of the tank. Loosen the hose clamp securing the filler neck to the tank using a flathead screwdriver or socket. Slide the clamp back on the hose. Disconnect the filler neck from the tank - it may require twisting while pulling. Disconnect the EVAP vent line from the tank by pressing the release tab and pulling the line free. Allow any residual fuel to drain into a pan.
   Torque spec

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

   Disconnect electrical connectors
   Locate the fuel pump module electrical connector on top of the fuel tank (accessible from above or may need to press connector down slightly to access). Press the locking tab and disconnect the connector. Disconnect any additional sender unit connectors if equipped with dual fuel tanks or auxiliary components. Mark connectors if multiple are present to ensure correct reconnection.
3. 3

   Disconnect fuel supply and return lines
   Identify the fuel supply line (larger diameter) and return line at the front of the fuel tank. Use the appropriate size fuel line disconnect tool for each fitting. Push the tool onto the line, then push the line into the fitting slightly while holding the tool in place, then pull the line free. Have a rag ready to catch residual fuel. Cap or plug the open lines to prevent contamination. Inspect O-rings and discard - new O-rings will be installed during reassembly.
   ⚠Fuel will spill from disconnected lines. Position drain pan and rags to contain spills.
4. 4

   Support fuel tank with jack
   Position the transmission jack or fuel tank jack directly under the center of the fuel tank. Raise the jack until it just contacts the tank bottom and provides slight support, but does not lift the tank. Use a block of wood between the jack and tank to distribute load and prevent tank damage. Ensure the tank is stable and balanced on the jack before proceeding.
5. 5

   Remove heat shield (if equipped)
   If your F-150 is equipped with a heat shield between the tank and exhaust, remove the mounting bolts securing it to the frame. The heat shield may be attached with 2-4 bolts. Set the heat shield aside for reinstallation. Note the orientation and position for reassembly.
6. 6

   Remove fuel tank strap bolts
   Locate the fuel tank strap mounting bolts at the front of each strap where they attach to the frame crossmember. These are typically 15mm bolts. Apply penetrating oil if bolts show corrosion. Remove the front mounting bolt from each strap but do not remove the straps yet. The straps will remain captured at the rear pivot point. Support the straps to prevent sudden release.
   ⚠Tank straps are under tension. Control the straps as bolts are removed to prevent sudden swinging that could cause injury or damage.
7. 7

   Lower fuel tank and remove straps
   Slowly and carefully lower the transmission jack, allowing the fuel tank to descend. Lower approximately 6-8 inches until the straps can swing free from the tank. Have an assistant guide the tank and straps if available. Once straps are clear, swing them forward and unhook from rear pivot points if applicable, or remove rear mounting hardware. Remove both straps from the vehicle. Inspect strap condition - look for cracks, severe corrosion, or deformation indicating replacement is necessary.
8. 8

   Inspect and clean mounting points
   With straps removed, inspect the frame mounting points for corrosion, damage, or deformation. Use a wire brush to clean mounting surfaces on the frame crossmember. Inspect the fuel tank mounting pads on the tank itself for damage. Apply a light coating of anti-seize compound to frame mounting bolt holes if corrosion is present. Inspect fuel tank for damage, dents, or corrosion while it is accessible.
9. 9

   Install new fuel tank straps
   Position the new fuel tank straps at their rear mounting points or pivot locations. Ensure straps are oriented correctly with the curved section matching the tank profile. If using pivot-style mounts, hook the rear of each strap onto its pivot. If using bolt-on rear mounts, install rear hardware finger-tight but do not torque yet. Swing straps up and position them to align with the tank once it is raised.
10. 10

    Raise fuel tank into position
    Carefully raise the transmission jack to lift the fuel tank back toward its mounting position. Guide the tank to ensure it seats properly in the frame cradle and aligns with strap locations. An assistant is highly recommended for this step. Raise the tank until it contacts the frame mounting pads but do not compress the straps yet. Ensure all electrical connectors and fuel lines remain clear and are not pinched.
11. 11

    Position and secure fuel tank straps
    Swing the fuel tank straps over the tank and align the front mounting holes with the frame crossmember holes. Install the front strap mounting bolts and thread them in by hand initially. Ensure straps are centered on the tank and not twisted. Once both front bolts are started, torque the strap mounting bolts to specification. If rear strap bolts were left loose, torque them now as well.
    ℹ️Straps should be snug but not over-tightened. Excessive torque can deform the tank.
    Torque spec

    Mounting Bolts34 Nm (25 lb-ft)
12. 12

    Reconnect fuel lines
    Install new O-rings on the fuel supply and return line fittings. Lightly lubricate the O-rings with clean engine oil or fuel. Push each fuel line firmly into its respective fitting until you hear and feel a positive click. Gently pull back on each line to verify it is locked in place. Ensure lines are not kinked, twisted, or under tension.
    Torque spec

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

    Reconnect electrical and vent connections
    Reconnect the fuel pump module electrical connector, ensuring it clicks into place securely. Reconnect any additional sender unit connectors. Reconnect the EVAP vent line by pushing it into the fitting until it clicks. Verify all electrical connections are secure and properly seated. Reconnect the fuel filler neck to the tank, slide the hose clamp into position, and tighten to specification.
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)
14. 14

    Reinstall heat shield and lower vehicle
    If equipped with a heat shield, position it between the exhaust and fuel tank, aligning mounting holes. Install and tighten heat shield mounting bolts. Remove the transmission jack from under the fuel tank. Reinstall the driver side rear wheel if it was removed and torque lug nuts to specification. Lower the vehicle to the ground.
15. 15

    Restore fuel system and check for leaks
    Reconnect the negative battery terminal. Reinstall the fuel pump fuse (fuse 27). Turn the ignition key to ON position (do not start) for 5 seconds, then OFF. Repeat this cycle 3-4 times to pressurize the fuel system and prime the pump. Inspect all fuel line connections, filler neck, and vent connections for any signs of fuel leakage. Check underneath the vehicle for drips. Only after confirming no leaks are present, start the engine and let it idle. Perform final leak inspection with engine running.
    ⚠️If any fuel leaks are detected, immediately turn off engine and relieve fuel pressure. Do not attempt to start or run vehicle until leak is repaired.

Reassembly

1. Ensure all fuel line connections are fully seated and locked before pressurizing system
2. Torque all strap mounting bolts to specification - do not overtighten as this can damage tank
3. Verify heat shield is properly positioned and does not contact exhaust or fuel tank
4. Double-check that all electrical connectors are fully engaged and locked

Verification

• Cycle ignition key ON/OFF 3-4 times and inspect all fuel connections for leaks before starting engine
• Start engine and verify it runs normally without fuel delivery issues or pressure loss
• Perform thorough visual inspection underneath vehicle for any fuel drips or seepage at all connection points
• Take a short test drive and re-inspect all connections afterward for any signs of leakage
• Monitor fuel gauge operation to confirm sender unit connections are functioning properly
• Verify no fuel odor is present in cabin or near vehicle after test drive

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