This procedure covers the complete removal and installation of the fuel tank on a 2021-2024 Ford F-150 with the 3.5L EcoBoost engine, including fuel system depressurization, tank strap removal, and all fuel line disconnections.

Warnings

Tools required

Parts

• Fuel tank (if replacing) × 1 — Use OEM specification
• Fuel tank strap set × 1 — Use OEM specification if corroded
• Fuel line O-ring kit × 1 — Use OEM specification
• Fuel filler neck hose clamps × 2 — Use OEM specification if damaged
• Fuel pump module gasket/seal × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake. Chock front wheels.
2. Relieve fuel system pressure: Remove fuel pump fuse (fuse 27 in battery junction box), start engine and let it run until it stalls, then crank for 5 seconds to ensure complete depressurization.
3. Disconnect negative battery terminal and wait 5 minutes for airbag system to discharge.
4. If tank is more than 1/4 full, use approved fuel transfer pump to drain into certified fuel storage containers.
5. Raise vehicle on lift or securely support on jack stands at all four corners. Vehicle must be level and stable.
6. Remove rear skid plate if equipped (4WD models may have different routing).
7. Position transmission jack or adjustable support under center of fuel tank but do not lift.

Procedure

1. 1

   Disconnect fuel filler neck
   Locate the fuel filler neck on the driver side rear quarter panel. Use hose clamp pliers to release the spring clamp at the tank connection point. Slide the clamp back on the filler neck hose. Twist and pull the filler neck hose to separate it from the tank inlet. Inspect for fuel spillage and have a drain pan ready.
   ⚠Residual fuel will drain from the filler neck. Position drain pan to catch spillage.
   Torque spec

   Filler Neck Clamp4 Nm (3 lb-ft)
2. 2

   Disconnect EVAP lines and vent hoses
   Identify the EVAP canister vent line and purge line connections on top of the fuel tank. Use appropriate quick-disconnect tool to release the spring clips on both lines. Press the release tabs and pull straight out. Cap or plug the lines to prevent contamination. Disconnect any additional vent hoses using hose clamp pliers.
   ℹ️Label all lines during removal to ensure correct reconnection. Take photos if needed.
3. 3

   Disconnect fuel supply and return lines
   Locate the fuel supply line and return line (if equipped) at the front of the fuel tank. These are high-pressure quick-disconnect fittings. Use the correct size Ford fuel line disconnect tool for each fitting. Insert the tool completely around the line, push toward the fitting, and pull the line straight out. Verify the O-rings remain with the tank fitting. Have a drain pan ready as pressurized fuel may still be present.
   ⚠️Even after depressurization, residual fuel under pressure may spray when disconnecting. Wear safety glasses and ensure no ignition sources nearby.
   Torque spec

   Fuel Line Fittings25 Nm (18 lb-ft)
4. 4

   Disconnect fuel pump electrical connector
   Locate the fuel pump module electrical connector on top of the tank. Press the locking tab and disconnect the connector. On some models, there may be a secondary connector for the fuel level sending unit. Disconnect all electrical connections and secure wiring harness away from tank.
5. 5

   Support fuel tank with transmission jack
   Position the transmission jack or adjustable jack stand directly under the center of the fuel tank. Raise jack until it just contacts the tank with light pressure. Ensure the tank is balanced and stable on the jack. Use a wide piece of wood or rubber pad between jack and tank to distribute load and prevent damage.
   ⚠️The tank must be properly balanced on the jack. An unbalanced tank can shift during lowering and cause crush injuries.
6. 6

   Remove fuel tank strap bolts
   Locate the two fuel tank support straps. Each strap is secured with a bolt at the front mount point. Using a socket and ratchet, remove the strap bolts. The straps are hinged at the rear and will swing down once the front bolts are removed. Support the straps as you remove the final bolt to prevent them from falling.
   ⚠The straps may be under tension. Control their movement as bolts are removed to prevent pinch points.
   Torque spec

   Tank Strap Bolts35 Nm (26 lb-ft)
7. 7

   Lower fuel tank partially and disconnect remaining lines
   Carefully lower the transmission jack 6-8 inches to create working clearance. Check for any remaining hoses, lines, or electrical connections that were not visible from below. Disconnect any remaining breather hoses or EVAP lines from the top of the tank. Verify all connections are released before proceeding.
   ⚠Do not force the tank downward. If resistance is felt, raise tank back up and identify any missed connections.
8. 8

   Remove fuel tank from vehicle
   With all connections verified as disconnected, slowly lower the transmission jack while guiding the tank clear of the frame rails and exhaust components. The tank will need to be angled and maneuvered slightly during removal. Once clear of the vehicle, lower completely and roll jack away from under vehicle. Use a second person to assist with balance and guidance if available.
   ⚠️Even a partially full tank is extremely heavy. Use proper lifting techniques and get assistance. Never rush this step.
9. 9

   Inspect and clean mounting area
   With tank removed, inspect the frame rails, tank straps, and mounting surfaces for corrosion, damage, or debris. Clean all mounting surfaces with wire brush and spray cleaner. Check tank strap bolts and threads for damage. Inspect the tank shield and heat shields for damage. Replace any corroded or damaged components.
10. 10

    Prepare tank for installation
    If reusing the tank, clean exterior surfaces and inspect for damage, dents, or corrosion. Replace the fuel pump module seal/gasket. Install new O-rings on all fuel line fittings using the O-ring kit. Lightly lubricate new O-rings with clean gasoline or approved fuel system lubricant. Ensure all mounting insulators are in place on the tank.
    ℹ️Never reuse old O-rings on fuel fittings. Always use new O-rings from the kit.
    Torque spec

    Fuel Line Fittings25 Nm (18 lb-ft)
11. 11

    Position tank and raise into place
    Place the fuel tank on the transmission jack with proper support and balance. Roll jack into position under vehicle. Carefully raise the tank up into the mounting location, ensuring it is centered between the frame rails. Align the tank with the strap mounting positions. Raise until tank is in final installed position but do not fully tighten straps yet.
12. 12

    Install and torque tank straps
    Swing the fuel tank straps up into position over the tank. Start both strap bolts by hand to ensure proper thread engagement. Tighten bolts in alternating pattern to draw straps evenly. Torque both tank strap bolts to specification using torque wrench. Verify tank is secure and positioned correctly.
    Torque spec

    Tank Strap Bolts35 Nm (26 lb-ft)
13. 13

    Reconnect fuel lines and EVAP lines
    Reconnect the fuel supply and return lines by pushing straight onto the tank fittings until an audible click is heard. Tug on each line to verify it is locked. Reconnect all EVAP vent and purge lines, ensuring they click into place. Reconnect any breather hoses and secure with clamps to specification.
    ℹ️Verify each quick-disconnect fitting is fully engaged. An improperly connected line can cause fuel leaks.
    Torque spec

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

    Reconnect electrical and filler neck
    Reconnect the fuel pump module electrical connector, ensuring the locking tab clicks into place. Reconnect the fuel level sensor connector if separate. Slide the fuel filler neck hose onto the tank inlet and position the clamp. Torque the filler neck clamp to specification.
    Torque spec

    Filler Neck Clamp4 Nm (3 lb-ft)
15. 15

    Final inspection and system pressurization
    Remove transmission jack from under vehicle. Reinstall any skid plates or shields removed during disassembly. Lower vehicle to ground. Reconnect negative battery terminal. Reinstall fuel pump fuse. Turn ignition to ON position (do not start) for 5 seconds, then OFF. Repeat this cycle 3-4 times to pressurize fuel system. Inspect all connections for leaks before starting engine.
    ⚠️Do not start engine until all connections have been visually inspected for leaks during pressurization cycles.

Reassembly

1. Ensure all quick-disconnect fittings are fully engaged and locked before pressurizing system
2. All torque specifications must be followed exactly - both under-torquing and over-torquing fuel system components can cause dangerous leaks
3. Double-check that no tools or parts were left on top of the fuel tank before lowering vehicle
4. Verify fuel filler cap is properly installed and sealing

Verification

• With engine running, inspect all fuel line connections, filler neck, and EVAP connections for leaks using a flashlight
• Check for fuel odors in cabin or near tank area - any fuel smell indicates a leak that must be corrected immediately
• Verify fuel gauge reads correctly and changes appropriately when ignition is cycled
• Test drive vehicle and monitor for any fuel system warning lights or driveability issues
• After first drive, re-inspect all connections from underneath for any seepage or wetness
• Verify no EVAP system codes are present using scan tool

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