Fuel Tank

Complete removal and replacement of the fuel tank on a 2015-2020 Ford F-150 with 5.0L V8 engine, including fuel system depressurization, tank strap removal, and fuel line disconnection.

Warnings

Tools required

Parts

• Fuel tank replacement × 1 — Use OEM specification
• Fuel line O-rings (assorted sizes) × 1 — Motorcraft CM-5278 or equivalent
• Fuel tank strap retainer nuts × 4 — Replace if corroded
• Filler neck clamp × 1 — Replace if damaged
• Tank shield hardware (if equipped) × 1 — Replace corroded fasteners

Preparation

1. Park vehicle on level surface outdoors or in well-ventilated area away from ignition sources
2. Ensure fuel tank is less than 1/4 full; use approved fuel transfer pump to drain excess fuel into approved containers if necessary
3. Disconnect negative battery terminal and wait minimum 10 minutes for electrical system to discharge
4. Raise vehicle on lift or secure on jack stands rated for truck weight, providing adequate clearance to lower fuel tank
5. Remove spare tire and lower spare tire carrier if it obstructs tank access
6. Have fire extinguisher immediately accessible throughout procedure
7. Prepare transmission jack or fuel tank support stand with wooden blocks to distribute load

Procedure

1. 1

   Depressurize fuel system
   Locate fuel pump fuse in battery junction box (fuse 27 on most 2015-2020 F-150 models - verify in owner's manual). Remove fuel pump fuse. Attempt to start engine; it should start briefly then stall as fuel pressure drops. Crank engine for additional 5-10 seconds to ensure complete depressurization. Leave fuse removed during entire procedure.
   ⚠️Fuel will still be present in lines even after depressurization. Have absorbent rags ready and avoid any ignition sources.
2. 2

   Remove fuel filler neck components
   Working from outside vehicle near fuel filler door, loosen filler neck clamp at tank connection using flathead screwdriver or 8mm socket. Disconnect filler neck hose from tank. Disconnect EVAP vent hose from filler neck. Disconnect fuel filler neck from body mount - may need to remove mounting bracket bolts.
   ⚠Some fuel may spill from filler neck. Have drain pan and rags ready.
   Torque spec

   Filler Neck Clamp4 Nm (3 lb-ft)
3. 3

   Disconnect EVAP system lines
   Locate EVAP canister mounted to front of fuel tank. Disconnect electrical connector from EVAP canister vent valve. Using spring-lock disconnect tool, disconnect EVAP vapor lines from canister (typically 2-3 lines). Note routing and connection points for reassembly. Label lines if necessary.
   ℹ️Take photos of EVAP line routing before disconnection for reference during reassembly.
4. 4

   Disconnect fuel feed and return lines
   Locate fuel feed line and return line connections at front of fuel tank. Use appropriate size Ford spring-lock coupling disconnect tool to release each connection. Push tool onto line, then pull line away from fitting. Fuel will drain from lines - capture in drain pan. Inspect O-rings on lines and fittings; discard old O-rings.
   ⚠️Even with depressurized system, residual fuel under slight pressure may spray when lines are disconnected. Wear safety goggles and have rags ready.
   Torque spec

   Fuel Line Fittings25 Nm (18 lb-ft)
5. 5

   Disconnect fuel pump module electrical connector
   Locate fuel pump module electrical connector on top of fuel tank (accessed from underneath vehicle). Press release tab and disconnect electrical connector. On some models, may need to remove protective cover first by releasing clips.
   ⚠Connector may be corroded or stuck. Do not force; use penetrating oil if necessary and allow time to work.
6. 6

   Remove tank shield and heat shields
   If equipped with skid plate or tank shield, remove mounting bolts using 13mm or 15mm socket. Remove any heat shields attached to tank or exhaust crossover pipes near tank. Set shields aside and inspect mounting hardware for corrosion - replace if necessary.
   Torque spec

   Mounting Bolts34 Nm (25 lb-ft)
7. 7

   Support fuel tank
   Position transmission jack or fuel tank support stand under center of fuel tank. Raise support until it just contacts tank bottom. Place wooden blocks between jack and tank to distribute load and prevent tank damage. Secure tank to jack with strap or chain to prevent shifting. Ensure tank is stable and well-supported.
   ⚠️Tank must be properly supported before loosening straps. Unsupported tank can fall suddenly causing crush injuries.
8. 8

   Remove fuel tank strap bolts
   Locate two fuel tank strap bolts at rear of tank on each side (4 bolts total on RWD models). Using 15mm socket with extension, remove all four tank strap bolts. Support straps as you remove final bolts - they will swing down once freed. Note strap orientation for reinstallation.
   ⚠Straps are under tension and will swing down forcefully when bolts are removed. Keep hands clear of strap path.
   Torque spec

   Tank Strap Bolts35 Nm (26 lb-ft)
9. 9

   Lower and remove fuel tank
   Slowly lower transmission jack while guiding tank downward. Watch for any remaining hoses, wires, or brackets still attached and disconnect if present. Lower tank approximately 6-8 inches and verify all connections are clear. Continue lowering tank completely and roll out from under vehicle. If installing new tank, transfer EVAP canister and any brackets from old tank to new tank.
   ⚠Lower tank very slowly and check continuously for forgotten connections. Forcing tank down with connections attached can cause fuel line damage or leaks.
10. 10

    Clean mounting area and inspect components
    With tank removed, clean tank mounting area on frame with wire brush. Remove dirt, rust, and debris. Inspect tank straps for corrosion, cracks, or damage - replace if compromised. Inspect all rubber isolators and mounts - replace if cracked or deteriorated. Clean threads on strap bolt locations.
    ℹ️This is ideal time to replace fuel pump module if showing signs of wear, as tank is already removed.
11. 11

    Position new tank and install straps
    If transferring components, ensure EVAP canister and all brackets are securely mounted to new tank. Position new or serviced tank on transmission jack and raise into position. Align tank with frame mounts and guide into place. Swing tank straps up and over tank. Start all four strap bolts by hand, ensuring straps are properly positioned and not twisted. Tighten strap bolts to specification in cross pattern (front right, rear left, front left, rear right).
    ⚠Do not fully tighten one strap before starting others. Tank must be evenly supported to prevent distortion.
    Torque spec

    Tank Strap Bolts35 Nm (26 lb-ft)
12. 12

    Reconnect fuel lines with new O-rings
    Install new O-rings on all fuel line fittings - discard old O-rings. Lightly lubricate new O-rings with clean engine oil or fuel. Push fuel feed and return lines onto tank fittings until they click into place - tug to verify secure connection. Install new O-rings on EVAP line fittings and reconnect vapor lines to canister. Verify all connections are fully seated.
    ⚠️Never reuse old fuel line O-rings. Degraded O-rings will cause fuel leaks leading to fire hazard.
    Torque spec

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

    Reconnect electrical and filler components
    Reconnect fuel pump module electrical connector - ensure it clicks securely. Reconnect EVAP canister vent valve connector. Position filler neck hose onto tank connection and install new filler neck clamp if old one was damaged. Tighten clamp to specification. Reconnect filler neck to body mount. Reconnect EVAP vent hose to filler neck.
    Torque spec

    Filler Neck Clamp4 Nm (3 lb-ft)
14. 14

    Reinstall shields and lower vehicle
    Reinstall any heat shields removed earlier. If equipped, reinstall tank skid plate or shield and torque mounting bolts to specification. Remove transmission jack from under tank. Raise spare tire carrier and reinstall spare tire if removed. Lower vehicle to ground.
    Torque spec

    Mounting Bolts34 Nm (25 lb-ft)
15. 15

    Pressurize system and leak check
    Reconnect negative battery terminal. Reinstall fuel pump fuse. Turn ignition to ON position (do not start engine) for 5 seconds, then OFF. Repeat 3-4 times to allow fuel pump to pressurize system. Inspect all fuel line connections, filler neck, and tank seams for leaks using flashlight. Check for wet spots or fuel smell. If no leaks present, start engine and allow to idle while continuing to monitor for leaks.
    ⚠️Any fuel leaks must be corrected immediately before operating vehicle. Even small leaks create serious fire hazard.
    ⚠Have fire extinguisher ready during initial startup and leak check.

Reassembly

1. Torque all fasteners to specifications using proper sequence where noted
2. Replace all fuel line O-rings - never reuse old O-rings
3. Ensure all electrical connectors click securely into place
4. Verify tank straps are properly positioned and not twisted before tightening
5. Route all fuel and EVAP lines in original positions away from sharp edges and heat sources

Verification

• Cycle ignition ON/OFF multiple times and inspect all connections for fuel leaks
• Start engine and verify no leaks during idle and light acceleration
• Check for fuel odors inside and outside vehicle
• Verify fuel gauge reads correctly
• Test drive vehicle and monitor for fuel delivery issues or leaks
• After first drive, re-inspect all connections for leaks or seepage
• Monitor for check engine lights related to fuel system or EVAP codes

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