This procedure covers the removal and replacement of the fuel cap on a 2021-2024 Ford F-150 with 3.5L EcoBoost engine.

Warnings

Tools required

Parts

• Fuel cap × 1 — Use OEM Ford fuel cap with correct thread pitch

Preparation

1. Park vehicle on level surface and turn off engine
2. Locate fuel filler door on passenger side rear quarter panel

Procedure

1. 1

   Open fuel filler door
   Press the rear edge of the fuel filler door on the passenger side of the vehicle to release the spring-loaded latch. The door will pop open.
2. 2

   Remove existing fuel cap
   Turn the fuel cap counterclockwise (left) approximately 1.5-2 full rotations until it releases from the filler neck threads. The cap may have a tether attached to prevent loss.
3. 3

   Inspect filler neck
   Check the fuel filler neck threads for damage, debris, or corrosion. Clean if necessary with a dry cloth. Inspect the cap tether attachment point if equipped to ensure it is secure.
4. 4

   Install new fuel cap
   Align the new fuel cap with the filler neck threads and turn clockwise (right) until you hear or feel multiple clicks (typically 3-4 clicks). This indicates proper sealing. Do not over-tighten beyond the clicking point.
5. 5

   Close fuel filler door
   Press the fuel filler door closed until it latches securely. Verify the door sits flush with the body panel.

Reassembly

1. No additional reassembly required for this procedure

Verification

• Start the engine and verify no check engine light appears related to evaporative emissions system
• Visually confirm fuel cap is properly seated and fuel door closes securely
• If check engine light was on prior to replacement, it may take several drive cycles to clear, or use an OBD-II scanner to clear codes after verifying proper installation

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