This procedure replaces the fuel level sensor in the fuel tank by removing the fuel pump module assembly to access and replace the level sensor.

Warnings

Tools required

Parts

• Fuel level sensor × 1 — Use OEM specification
• Fuel pump module O-ring seal × 1 — Use OEM specification
• Fuel line O-rings × 2 — Use OEM specification

Preparation

1. Ensure fuel tank is less than 1/4 full. If tank is more full, siphon fuel into approved containers.
2. Park vehicle on level surface and engage parking brake.
3. Disconnect negative battery terminal and wait 2 minutes to allow fuel pump to depressurize.
4. Relieve any remaining fuel system pressure by removing fuel pump fuse and attempting to start engine until it will not run.
5. Raise and safely support rear of vehicle on jack stands.
6. Place fuel catch container under work area to catch spillage.

Procedure

1. 1

   Access fuel tank
   Remove the fuel tank skid plate or protective shield if equipped. Remove mounting bolts securing the shield to frame. Note that 2021-2024 F-150 models have fuel pump access through the bed, not requiring full tank removal.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
2. 2

   Lower spare tire and heat shield
   Lower the spare tire completely out of the way. Remove the fuel tank heat shield by removing the mounting bolts. This provides access to the fuel tank top.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
3. 3

   Disconnect fuel lines
   Using fuel line disconnect tools, disconnect the fuel supply and return lines from the fuel pump module. Press the tabs on the quick-connect fittings while pulling the lines away. Have shop towels ready to catch residual fuel. Cap or plug the lines to prevent contamination.
   ⚠Residual fuel will drain from lines. Position towels to catch spillage and dispose of properly.
4. 4

   Disconnect electrical connector
   Locate the fuel pump module electrical connector on top of the tank. Depress the locking tab and carefully disconnect the connector. Clean any dirt or debris from the area around the fuel pump module before proceeding.
5. 5

   Remove fuel pump lock ring
   Using the fuel tank lock ring tool, rotate the fuel pump module lock ring counterclockwise until it releases. The lock ring has directional arrows marked on it. Remove the lock ring completely and set aside.
   ⚠Do not use a hammer and chisel on the lock ring as this can create sparks or damage the ring.
6. 6

   Remove fuel pump module
   Carefully lift the fuel pump module assembly straight up and out of the fuel tank. Tilt the module slightly to clear the fuel level sensor float arm from the tank opening. Be aware that fuel will drain from the module. Hold the module over the tank opening to allow fuel to drain back, then place in a fuel catch container.
   ⚠The fuel level sensor float arm extends from the bottom of the module and can be damaged if not handled carefully.
7. 7

   Drain and clean module
   Allow remaining fuel to drain from the fuel pump module into the catch container. Wipe down the exterior of the module with clean shop towels. Inspect the module O-ring seal and replace if damaged, compressed, or showing any signs of wear.
8. 8

   Remove fuel level sensor
   Locate the fuel level sensor on the side of the fuel pump module. It is secured by a plastic clip or tab mechanism. Carefully depress the locking tab and slide the sensor out of its mounting bracket. Disconnect the electrical connector from the sensor by depressing the tab and pulling apart.
   ℹ️Take photos before disconnecting to ensure correct reinstallation of sensor position and orientation.
9. 9

   Install new fuel level sensor
   Connect the electrical connector to the new fuel level sensor until it clicks into place. Slide the sensor into the mounting bracket on the fuel pump module, ensuring the locking tab fully engages. Verify the float arm moves freely through its full range of motion without binding.
   ⚠Ensure the sensor is oriented correctly with the float arm positioned to match the removed sensor. Incorrect orientation will cause inaccurate fuel level readings.
10. 10

    Install new O-ring seal
    Remove the old O-ring seal from the top of the fuel pump module. Clean the O-ring groove thoroughly with a clean shop towel. Install the new O-ring seal into the groove, ensuring it seats completely around the entire circumference without twisting or pinching.
11. 11

    Reinstall fuel pump module
    Carefully lower the fuel pump module assembly into the fuel tank opening. Angle the module to clear the float arm, then align the module with the tank opening. Ensure the module seats fully against the O-ring seal. The alignment marks on the module and tank should line up.
    ⚠Do not force the module into position. If it does not seat easily, remove and check for obstructions or misalignment.
12. 12

    Install lock ring
    Position the fuel pump module lock ring over the module and align with the tank threads. Using the lock ring tool, rotate the ring clockwise following the directional arrows until it is fully tightened. The lock ring should be snug and secure without excessive force.
    ℹ️Ford does not specify a torque value for the lock ring. Tighten until seated firmly against the stops.
13. 13

    Reconnect fuel lines and electrical
    Install new O-rings on the fuel line fittings. Reconnect the fuel supply and return lines to the fuel pump module, pushing each fitting until it clicks into place. Tug gently on each line to verify secure connection. Reconnect the electrical connector to the fuel pump module until it clicks and locks.
    Torque spec

    Fuel Line Fittings25 Nm (18 lb-ft)
14. 14

    Reinstall heat shield and access covers
    Reinstall the fuel tank heat shield and secure with mounting bolts. Raise the spare tire back into position. Reinstall the fuel tank skid plate or protective shield if removed.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)

Reassembly

1. Reconnect negative battery terminal.
2. Turn ignition to ON position (do not start) for 10 seconds to prime fuel system. Turn OFF, wait 5 seconds, then repeat 3 times.
3. Check all fuel line connections for leaks while system is pressurized.
4. Lower vehicle from jack stands after confirming no leaks.

Verification

• Start engine and verify it runs smoothly without fuel delivery issues.
• Check for any fuel leaks at the pump module and fuel line connections.
• Verify fuel gauge reads correctly by comparing displayed level to actual fuel level in tank.
• Test drive vehicle and monitor fuel gauge operation through normal driving conditions.
• Add fuel to tank and verify gauge responds appropriately to fuel level changes.

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