Fuel Tank: Service and Repair

FUEL TANKS





Removal
1. Disconnect battery ground cable.

NOTE: On vehicles equipped with EEC, when the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the EEC processor relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy.

2. Using Rotunda 034-00001 Fuel Storage Tanker or equivalent drain fuel tank.
3. Raise the rear of the vehicle.
4. To avoid electrical sparking at the tank, disconnect the ground cable on the vehicle battery.
5. Loosen the clamp on the fuel filler pipe hose at the filler pipe and disconnect the hose from the pipe by pulling along the internal fuel tube from the tank filler neck.
6. Disconnect fuel delivery module (FDM) connector.
7. Disconnect fuel line push connectors and fuel vapor lines.
8. Support the tank and remove the lower support bracket bolts or skid plate bolts.
Remove the support assembly or skid plate attaching nut at each tank mounting strap.
Lower the support assemblies, and lower the tank enough to gain access to the tank vent hose.

9. Remove the fuel tank from under the vehicle.
10. If necessary, remove retaining ring with Fuel Tank Sender Wrench D84P-9275-A or equivalent, then remove FDM and gasket.
Fuel gauge unit may be separated from fuel pump and reservoir assembly.


Installation
1. If removed, install new gasket and FDM. Make sure FDM tabs are seated in slots in gas tank and that retainer ring is tightened until tabs are positioned between detente and stop on tank.
Use Fuel Tank Sender Wrench D84P-927 5-A or equivalent.

. Position the forward edge of the tank and skid plate, if so equipped, to the frame crossmember, support the tank and connect the vent hose to the top of the tank.
3. Connect the FDM electrical connector.
4. Position the tank, skid plate and straps, and install the attaching parts.
Tighten the attaching bolts and nuts to 37 - 50 Nm (27 - 37 ft.lb.) using Ford Threadlock and Sealer EOAZ- 1 9554-A or equivalent.

5. Connect the fuel lines to the FDM.
6. Insert the internal fuel tube into the tank filler neck. Connect the filler pipe-to-tank hose and vent tube at the filler pipe and install the hose clamp.
Tighten to 3 - 4 Nm (25 - 35 in.lb.).

7. Connect the vehicle battery ground cable.
8. Fill the tank and check all connections for leaks.
9. Lower the vehicle.