Fuel Tank: Removal

NOTE: This procedure is considered a major service repair. For Ford warranty coverage, the vehicle must be returned to the Multimatic vehicle assembly and repair facility.

All vehicles

Drain the fuel tank. Refer to: Fuel Tank Draining .
Remove the rear frame structure and powertrain. Refer to: Rear Frame Structure and Powertrain .
- Loosen the clamp.
- Remove the bolts and the fuel tank filler pipe.
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- Remove the lower bolts.
- Loosen the top bolt and position aside the bracket.
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Remove the bolts and the LH access panel.

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- Remove the lower bolts.
- Loosen the top bolt and position aside the bracket.
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Remove the bolts and the RH access panel.

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Remove the bolts and the engine bulkhead panel.

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Disconnect the fuel level sender electrical connector.

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- Disconnect the fuel pump electrical connectors.
- Remove the nuts and bolts and position aside the wire harness.
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Disconnect and remove the fuel pump relays.

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Disconnect the fuel pump electrical connector.

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Disconnect and remove the fuel lines. Refer to: Quick Release Coupling .

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With the help of an assistance, remove the fuel tank.

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Vehicles with fuel remaining in the fuel tank
Remove the bolts and the fuel level sender.

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Insert the hose from the Fuel Tanker and drain the remaining fuel from the fuel tank. Use Special Service Tool: 292-00004 Fuel Tanker 100 GPM.
Install the fuel level sender and the bolts.
Torque: 18 lb.in (2 Nm)

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All vehicles
Loosen the clamp and remove the fuel tank hose.

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