Fuel Filler Neck

This procedure covers the removal and replacement of the fuel filler neck assembly on a 2021-2024 Ford F-150 with the 3.5L EcoBoost V6 engine, including disconnection of hoses and clamps.

Warnings

Tools required

Parts

• Fuel filler neck assembly × 1 — Use OEM specification
• Fuel filler neck hose clamps × 2 — Replace if corroded
• Fuel filler neck seal/grommet × 1 — Use OEM specification

Preparation

1. Ensure fuel tank is less than 1/4 full to minimize spillage
2. Park vehicle on level ground and engage parking brake
3. Raise and safely support the rear driver's side of the vehicle using jack and jack stands
4. Remove the driver's side rear wheel for improved access (optional but recommended)
5. Place drain pan underneath the filler neck area to catch residual fuel
6. Have shop towels ready to absorb fuel spillage

Procedure

1. 1

   Remove fuel door and access panel
   Open the fuel door. Locate and remove the screws securing the fuel filler door assembly if full removal is needed for access. From underneath, locate any plastic access panels or splash shields that may obstruct access to the filler neck. Remove fasteners and set aside panels.
2. 2

   Disconnect filler neck vent hose
   Locate the small vent hose connected to the upper portion of the filler neck assembly. Using hose clamp pliers or flathead screwdriver, loosen the hose clamp and slide it away from the connection point. Carefully twist and pull the vent hose off the filler neck. Expect small amount of fuel vapor.
3. 3

   Disconnect main fuel filler hose
   Locate the large fuel filler hose that connects the filler neck to the fuel tank. Position drain pan directly underneath this connection. Loosen the hose clamp securing the filler hose to the filler neck. Slide the clamp back along the hose, then carefully work the hose off the filler neck. Residual fuel will drain; allow it to fully empty into drain pan.
   ⚠Expect significant fuel spillage when disconnecting this hose. Ensure drain pan is properly positioned.
4. 4

   Remove filler neck mounting bolts
   Locate the mounting bolts that secure the filler neck to the body panel. There are typically 3-4 bolts around the circumference where the neck enters the body. Using appropriate socket, remove all filler neck mounting bolts. Support the filler neck assembly as you remove the final bolt to prevent it from falling.
   Torque spec

   Filler Neck Bolts10 Nm (7 lb-ft)
5. 5

   Remove filler neck assembly
   Carefully maneuver the filler neck assembly out through the body opening from underneath the vehicle. You may need to rotate and angle the assembly to clear the body panel and surrounding components. Once free, remove completely and set aside. Inspect the rubber grommet/seal in the body panel for damage or deterioration.
6. 6

   Inspect and clean mounting area
   Inspect the fuel tank filler hose connection point for cracks, damage, or deterioration. Check the vent hose connection for damage. Clean the body panel mounting surface and remove any old seal material or debris. Wipe away any spilled fuel from surrounding components.
7. 7

   Prepare new filler neck assembly
   Compare new filler neck assembly to old unit to verify correct part. Install new rubber grommet/seal into the body panel opening if replacement is included. Lubricate the seal lightly with soapy water if needed to ease installation. Ensure new hose clamps are available if old clamps show corrosion.
8. 8

   Install new filler neck assembly
   From underneath the vehicle, carefully guide the new filler neck assembly up through the body panel opening. Rotate and angle as needed to properly seat the neck through the grommet. Align the mounting holes with the body panel. Hand-thread all filler neck mounting bolts before tightening any of them.
9. 9

   Torque filler neck bolts
   Using a torque wrench, tighten all filler neck mounting bolts to specification in a cross-pattern to ensure even seating. Verify the filler neck is properly seated in the body panel grommet and aligned correctly before final tightening.
   Torque spec

   Filler Neck Bolts10 Nm (7 lb-ft)
10. 10

    Reconnect main filler hose
    Slide a new or existing hose clamp onto the fuel tank filler hose. Push the filler hose firmly onto the filler neck connection until it is fully seated. Position the hose clamp over the connection point on the ribbed section of the filler neck. Tighten the hose clamp to specification ensuring even pressure around the circumference.
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)
11. 11

    Reconnect vent hose
    Slide hose clamp onto the vent hose. Push the vent hose firmly onto the filler neck vent connection until fully seated. Position the clamp over the connection and tighten to specification. Ensure the vent hose routing matches the original configuration with no kinks or sharp bends.
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)
12. 12

    Reinstall access panels
    Reinstall any splash shields or access panels that were removed for access. Secure all fasteners. If the rear wheel was removed, reinstall and torque lug nuts to specification. Lower vehicle from jack stands.

Reassembly

1. Verify all hose clamps are properly tightened and positioned
2. Ensure no tools or parts are left in the work area
3. Double-check that all mounting bolts are torqued to specification
4. Wipe down any fuel residue from components and body panels

Verification

• Add 2-3 gallons of fuel to the tank through the filler neck
• Inspect all connections underneath the vehicle for fuel leaks while fueling
• After fueling, start the engine and let it idle for 2-3 minutes
• Re-inspect all filler neck connections for any signs of fuel seepage or vapor leaks
• Test the fuel cap for proper seating and verify no check engine light appears
• Verify the evaporative emissions system check passes (may require short drive cycle)
• Clean any spilled fuel and dispose of fuel-contaminated materials properly

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