Fuel Tank Strap

Replace the fuel tank support straps that secure the fuel tank to the vehicle frame, requiring fuel tank lowering and removal of associated components.

Warnings

Tools required

Parts

• Fuel tank strap(s) × 2 — Use OEM specification
• Fuel line O-rings × 4 — Use OEM specification
• Strap mounting bolts/nuts × 4 — Use OEM specification

Preparation

1. Park vehicle on level, hard surface with adequate overhead clearance for jack operation
2. Disconnect negative battery terminal and wait 5 minutes to allow fuel pump circuit to depressurize
3. Remove fuel cap to release tank pressure
4. If tank is more than 1/4 full, drain fuel using approved fuel transfer pump into approved storage container
5. Raise vehicle securely on jack stands at manufacturer-specified lift points, minimum 24 inches of ground clearance
6. Remove spare tire and lower it from storage location if equipped (provides access to tank)
7. Place wheel chocks on front wheels
8. Ensure transmission jack or fuel tank jack is available and in good working condition

Procedure

1. 1

   Relieve fuel system pressure
   Locate the fuel pump fuse or relay in the power distribution box (typically fuse 45 or relay R6 for 2021-2024 F-150). Remove the fuse/relay, then attempt to start the engine. Allow it to run until it stalls. Attempt to restart 2-3 times until engine will not fire. This confirms fuel pressure is relieved. Replace fuse/relay but leave battery disconnected.
2. 2

   Remove heat shields and protective covers
   From under the vehicle, locate and remove the exhaust heat shields that protect the fuel tank (typically 3-4 shields secured with 10mm bolts). Remove any underbody plastic splash shields or skid plates that obstruct tank access. Set aside hardware in organized manner.
3. 3

   Disconnect fuel filler neck and vent lines
   At the rear of the tank near the filler neck, loosen the hose clamps securing the fuel filler neck hose and vent hoses to the tank. Use fuel line disconnect tools if quick-connect fittings are present. Carefully work hoses free from tank connections. Cap or plug openings to prevent contamination.
   ⚠Fuel residue will drain from filler neck. Have drain pan positioned below connection point.
   Torque spec

   Hose Clamps3 Nm (2 lb-ft)
4. 4

   Disconnect fuel supply and return lines
   Locate the fuel supply line (typically 3/8 inch) and return line (typically 5/16 inch) at the front of the tank. Use appropriate fuel line disconnect tool for the quick-connect fitting type. Press the tool onto the fitting and pull the line straight out. Inspect O-rings and discard - new O-rings will be installed during reassembly. Plug lines immediately to prevent contamination.
   ⚠Residual fuel will spray when lines are disconnected. Wear safety glasses and have absorbent material ready.
5. 5

   Disconnect electrical connectors
   Locate the fuel pump module electrical connector on top of the tank (accessible from rear of vehicle). Press the locking tab and disconnect the connector. Also disconnect any EVAP canister electrical connectors and fuel level sensor connectors if separately wired. Use electrical contact cleaner on connectors if corrosion is present.
6. 6

   Disconnect EVAP vapor lines
   Locate the EVAP canister vapor lines connecting to the tank (typically 2-3 lines with quick-connect fittings). Use fuel line disconnect tools to release each fitting. Note routing and orientation for reinstallation. Some models have the EVAP canister mounted to the tank - if so, it will lower with the tank.
7. 7

   Position transmission jack under tank
   Position the transmission jack or fuel tank jack directly under the center of the fuel tank. Adjust jack height so the saddle contacts the tank bottom but does not support weight yet. Use wood blocks or specialized tank saddle to distribute load and prevent tank damage. Ensure tank is stable on jack before proceeding.
   ⚠️Tank must be properly centered and secured on jack. Improper positioning can cause tank to fall during lowering, creating fire hazard and crush injury risk.
8. 8

   Remove fuel tank strap fasteners
   Locate the two fuel tank strap bolts or nuts at each end of both straps (typically 15mm or 18mm). The straps run front-to-back under the tank. Apply penetrating oil to fasteners if corrosion is visible. Support straps by hand or wire while removing the rear fasteners first on each strap, then loosen but do not fully remove the front fasteners. Raise jack slightly to support tank weight.
   ⚠Fasteners may be severely corroded. Use 6-point sockets and apply steady pressure to avoid rounding off bolt heads.
9. 9

   Remove tank straps
   With tank weight supported by jack, remove the front strap fasteners completely. Carefully guide the straps down and out from around the tank. Inspect straps for corrosion, cracks, or deformation - replace if any damage is present. Clean mounting surfaces on frame with wire brush.
10. 10

    Lower fuel tank
    Slowly lower the transmission jack while guiding the tank down. Watch for any remaining connections that were missed. Lower tank approximately 12 inches to provide access to top-mounted components if needed, or lower completely if full strap replacement requires more access. Control descent carefully to prevent damage.
    ⚠️Never allow any part of your body under an unsupported fuel tank. Keep face and body clear of tank in case of fuel leak during lowering.
11. 11

    Install new fuel tank straps
    Position new fuel tank straps in the frame mounting points. If reusing original straps (after inspection confirms acceptable condition), clean thoroughly with wire brush and inspect rubber isolators. Raise tank on jack to align with strap positions. Guide straps around tank and align with mounting holes on opposite side of frame.
12. 12

    Install and torque strap fasteners
    Install new strap mounting bolts or nuts finger-tight at all four positions (two per strap). Ensure straps are properly seated against frame brackets and tank is centered in vehicle. Torque all four fasteners to specification in a cross pattern (front left, rear right, front right, rear left). Verify tank is secure and does not shift.
    ⚠Do not over-torque strap fasteners as this can deform tank or crack strap mounting brackets.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
13. 13

    Reconnect fuel and vapor lines
    Install new O-rings on all fuel line fittings (lubricate lightly with clean gasoline or O-ring lubricant). Push fuel supply and return lines straight onto tank fittings until a distinct click is heard. Tug on each line to verify secure connection. Reconnect EVAP vapor lines ensuring proper routing matches original configuration.
    ⚠Ensure O-rings are properly seated in fitting grooves before connection. Cross-threaded or improperly seated fittings will leak.
    Torque spec

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

    Reconnect filler neck and electrical
    Reconnect fuel filler neck hose and vent hoses to tank connections. Install new hose clamps and tighten to specification. Reconnect fuel pump module electrical connector, EVAP canister connector, and any other electrical connections. Ensure all connector locks engage fully.
    Torque spec

    Hose Clamps3 Nm (2 lb-ft)
15. 15

    Reinstall shields and lower vehicle
    Reinstall all heat shields, skid plates, and underbody protection panels removed during disassembly. Torque shield fasteners to specification if torque values were provided, otherwise tighten securely. Remove transmission jack. Carefully lower vehicle from jack stands. Reinstall spare tire if removed.

Reassembly

1. Reconnect negative battery terminal and ensure good connection
2. Add fuel to tank if it was drained (minimum 2 gallons for initial testing)
3. Do NOT attempt to start engine yet - proceed to verification steps first

Verification

• Turn ignition to ON position (do not start engine) and listen for fuel pump to run for 2-3 seconds, then cycle ignition off and on 3-4 times to pressurize system
• Inspect all fuel line connections, filler neck, and tank seams for fuel leaks while system is pressurized
• Start engine and allow to idle for 5 minutes while continuing to inspect for leaks from underneath vehicle
• With engine running, check for proper fuel pressure and smooth engine operation - any hesitation may indicate air in fuel lines
• Perform visual inspection of tank strap alignment and verify tank sits level and centered in vehicle
• Road test vehicle and monitor for fuel smell in cabin, unusual noises from tank area, or fuel gauge irregularities
• After road test, perform final leak inspection of all connections with vehicle on level ground
• If any fuel odor or leaks are detected, do NOT drive vehicle - shut off engine immediately and re-inspect all connections

More procedures for this vehicle