This procedure replaces the fuel pump module in a 2021-2024 Ford F-150 3.5L EcoBoost by accessing it through the bed-mounted service panel, requiring fuel system depressurization and electrical disconnection.

Warnings

Tools required

Parts

• Fuel pump module assembly × 1 — Motorcraft PFS-570 or equivalent OEM
• Fuel pump module O-ring seal × 1 — Usually included with pump module
• Fuel line quick connect O-rings × 2 — Use OEM specification

Preparation

1. Park vehicle on level ground outdoors or in well-ventilated shop area. Ensure no ignition sources within 50 feet.
2. Engage parking brake and place transmission in Park.
3. Turn ignition off and remove key. Disconnect negative battery terminal and isolate cable away from battery post. Wait 2 minutes for system capacitors to discharge.
4. If fuel tank is more than 1/4 full, siphon fuel to a safe approved container to minimize spillage during removal. Do NOT drain tank completely as some fuel must remain to cushion pump during handling.
5. Chock front wheels. Raise rear of vehicle if needed for access clearance, though most F-150s allow bed access without lifting.
6. Place absorbent pads and catch pan under work area.
7. Allow engine and exhaust system to cool completely if vehicle was recently operated (minimum 1 hour).

Procedure

1. 1

   Access fuel pump service cover
   For 2021-2024 F-150, the fuel pump access panel is located under the rear seat or in the bed depending on configuration. For crew cab models, fold up the rear seat bottom cushion to expose the access cover on the floor. For regular cab or if panel is bed-mounted, locate the rectangular access cover in the truck bed floor forward of the rear axle, typically on the driver side. Remove any bed mat or liner covering the panel.
2. 2

   Remove access cover screws
   Using T30 Torx bit, remove the access cover screws (typically 6-8 screws). Carefully lift the access cover away. You should now see the top of the fuel pump module and connected fuel lines. Clean any dirt or debris from around the pump module area before proceeding.
3. 3

   Relieve fuel system pressure
   Locate the fuel pump electrical connector on top of the module. Press the locking tab and disconnect the electrical connector. Reconnect the negative battery cable temporarily. Turn ignition to ON position (do not start engine) for 3 seconds, then OFF. Repeat this cycle 5-6 times to cycle the fuel pump relay and depressurize the system through the returnless regulator. Attempt to start the engine; it should crank but not start or run very briefly. When engine will no longer start, pressure is relieved. Turn ignition OFF and disconnect negative battery cable again. Verify pressure relief by attaching fuel pressure gauge to the Schrader valve on the fuel rail if accessible; pressure should read 0 PSI.
   ⚠️Even after this procedure, some residual pressure and fuel spillage will occur. Have catch pan and rags ready for next steps.
4. 4

   Disconnect fuel supply line
   Identify the fuel supply line (larger diameter line) connected to the pump module. Using the appropriate size fuel line disconnect tool, press the tool into the quick-connect fitting while pulling the line away from the module. You will feel a click as the internal retainer releases. Some fuel will spill; direct it into the catch pan. Inspect the line end for damaged O-ring; replace O-rings if worn or cut. Cap or plug the fuel line to prevent contamination.
   ⚠Do not use excessive force or pry tools on quick-connect fittings as this will damage the internal locking mechanism.
5. 5

   Disconnect fuel return line and EVAP line (if equipped)
   Using appropriate disconnect tools, remove the return line (smaller diameter) and any EVAP vapor line connected to the pump module using the same quick-connect procedure as the supply line. Some fuel vapor or liquid may release. Cap all disconnected lines to prevent dirt intrusion.
6. 6

   Remove fuel pump module lock ring
   Using the Ford fuel pump lock ring tool (310-123 or equivalent aftermarket tool that fits the module), position the tool tabs into the lock ring notches. Strike the tool handle counterclockwise with a plastic mallet or turn firmly counterclockwise by hand to loosen the lock ring. The lock ring is typically hand-tight but may require significant force. Once loose, unscrew the lock ring completely by hand and remove it. Note the orientation of any alignment marks on the ring and tank.
   ⚠Do NOT use metal hammers or strike near the tank opening as sparks could ignite fuel vapors.
   Torque spec

   Fuel Pump Module Lock Ring80 Nm (59 lb-ft)
7. 7

   Remove fuel pump module assembly
   Carefully lift the fuel pump module assembly straight up and out of the tank opening. The module includes the pump, fuel level sender, and associated bracket. Tilt the module slightly to maneuver the fuel level float arm and pump assembly through the opening without bending the float arm. As you remove the module, fuel will drain back into the tank; have rags ready. Once clear, place the old module in a catch pan to drain. Keep the assembly upright to avoid spilling residual fuel.
   ⚠The fuel level sender float arm is delicate. Bending it will cause inaccurate fuel gauge readings.
8. 8

   Inspect tank opening and remove old seal
   With the module removed, inspect the inside of the tank opening for debris, rust, or contamination. If debris is visible, use a clean lint-free cloth slightly dampened with fresh gasoline to wipe the sealing surface. Do NOT allow any debris to fall into the tank. Remove the old rubber O-ring seal from the tank opening groove. Inspect the groove for damage or corrosion.
9. 9

   Prepare and install new fuel pump module
   Remove the new fuel pump module from packaging. Verify the new module matches the old unit in connector design and orientation. Install the new O-ring seal (usually supplied with the pump module) into the groove on the tank opening. Lightly lubricate the O-ring with clean gasoline (not petroleum jelly or oil). Carefully insert the new pump module into the tank opening at the correct orientation, guiding the fuel level float arm through without bending it. Press the module down until it seats fully against the O-ring seal.
10. 10

    Install and torque fuel pump lock ring
    Place the lock ring over the pump module, aligning any orientation marks noted during removal. Thread the lock ring clockwise by hand until it contacts the tank flange. Using the fuel pump lock ring tool, tighten the lock ring to 80 Nm (59 lb-ft) torque specification. Ensure even seating by checking that the lock ring is flush with the tank surface around the entire circumference.
    Torque spec

    Fuel Pump Module Lock Ring80 Nm (59 lb-ft)
11. 11

    Reconnect fuel lines
    Inspect all quick-connect fittings and install new O-rings where provided in the parts kit. Remove caps from fuel lines. Align each fuel line (supply, return, EVAP) with its respective port on the pump module. Push each line straight onto the module port until you hear and feel a distinct click, indicating the internal retainer has locked. Gently pull back on each line to verify it is secured and will not release.
    ⚠Failure to fully seat quick-connect fittings will result in fuel leaks and potential fire hazard.
12. 12

    Reconnect fuel pump electrical connector
    Clean the electrical connector terminals if any corrosion is visible. Align the fuel pump electrical connector with the module connector and push together firmly until the locking tab clicks into place. Verify the connection is secure by gently pulling on the connector body.
13. 13

    Reinstall access cover
    Clean the access cover and surrounding area of any fuel residue or debris. Position the access cover over the opening, aligning screw holes. Install all access cover screws and tighten in a cross-pattern to 4.0 Nm (3.0 lb-ft) using T30 Torx bit and torque wrench to ensure even sealing.
14. 14

    Reconnect battery and prime fuel system
    Reconnect the negative battery cable and tighten securely. Turn the ignition to ON position (do not start) for 5 seconds, then OFF. Repeat this cycle 4-5 times to allow the new fuel pump to prime the system and build pressure. Listen for the fuel pump running during each ON cycle (a humming sound from the tank area). Do not crank the engine yet.
15. 15

    Inspect for leaks and test operation
    With ignition ON (engine not running), carefully inspect all fuel line connections at the pump module for any signs of fuel leakage. Look for wet spots or fuel odor. If no leaks are observed, start the engine. The engine may crank longer than normal on first start as the system fully pressurizes. Once running, inspect again for leaks with engine at idle. Check fuel pressure with gauge if available; should be 55-65 PSI. Allow engine to idle for 2-3 minutes while monitoring for leaks or unusual sounds.
    ⚠️If any fuel leak is detected, immediately turn OFF ignition and relieve pressure. Do not operate vehicle until leak is corrected.

Reassembly

1. Ensure access cover is fully secured with all screws torqued to specification to prevent fuel vapor escape into cabin
2. If rear seat was removed for access, reinstall seat cushion ensuring it latches properly
3. Replace any bed liner or mat that was removed for access
4. Remove all tools, rags, and catch pans from vehicle
5. Properly dispose of fuel-contaminated rags in approved metal container

Verification

• Start engine and verify normal operation with no rough idle, hesitation, or fuel odor in cabin
• Check that fuel gauge reads accurately and matches known fuel level
• Perform a test drive and verify normal acceleration and no fuel pump whine or abnormal noise
• After test drive, re-inspect all fuel connections at the pump module for any seepage or leaks
• Use OBD-II scanner to verify no fuel system related diagnostic codes are present (P0087, P0230, P0461, etc.)
• Monitor fuel system for 24-48 hours of normal driving to ensure no delayed leak development

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