Replacing Ford 20 Fuel Tank: Step-By-Step Guide For Diyers

If you're having trouble firing up your Ford F-150 or Super Duty engine or are experiencing strange idling, it could be that your fuel pump is on its last legs. The fuel pump is a component that can wither over time and, because it's located in your fuel tank, there is no easy way to get to it. You will have to remove your truck bed or fuel tank. Here's how to do it.

Siphoning gas from the tank

Siphoning gas from a Ford vehicle can be tricky because newer cars have small fuel filler openings and spring-loaded flaps to stop fuel vapors from escaping. In addition, most new vehicles have a blocking mechanism at the bottom end of the filler neck to prevent pushing a siphon hose into the gas tank.

Using a Siphon Pump:

• Place a gas can on the ground beneath the tank and run the tubing from the tank to the can. Ensure that the correct ends of the tubing are being used, as siphon pumps have designated ends for liquid to enter and exit.
• Pump when ready. Hand-operated pumps usually require you to grab a plunger and push in and out or squeeze an inflatable bulb, while mechanical pumps may only need you to flip a switch.
• When you near your desired amount of gas, raise the end of the tubing or the container itself to stop the flow. This will cause any residual gas in the pump to drain back into the tank.
• Remove the siphon pump from the tank when it is free of excess gas.

Creating Pressure in the Tank:

• Find a gas can or another closed container to siphon the gas into. It is important to use a closed container to prevent spilling gasoline or inhaling fumes.
• Obtain clear plastic tubing that is 1 inch (2.5 cm) in diameter. You will need two lengths of tubing: one long enough to reach deep into the gas tank and another shorter length that will reach just inside the tank.
• Set the gas can on the ground near the opening of the car's gas tank. Feed both tubes into the tank, pushing the longer length well into the gas tank and the shorter length just a few inches so that they sit side-by-side.
• Use a rag to create a seal around the tubes. This method works by increasing air pressure in the tank to displace the gas. Pack a cheap rag or towel around the tubes to prevent air from escaping the tank.
• Force air into the short tube to increase the air pressure inside the tank. You can blow into the tube with your lungs or use a mechanical air pump.
• Monitor the flow of gas. As you blow into the gas tank, you should see the gas move through the longer length of tubing and into your gas can. Once the gas is flowing freely, gravity will do the rest of the work.
• When you want to stop siphoning, cover the long tube with your thumb, raise it above the level of gas in the tank, and remove your thumb. Any remaining gas in the tube should flow back into the tank.

Traditional Mouth Siphoning (Not Advised):

• Understand the dangers of gasoline poisoning. Gasoline contains hydrocarbons, which are poisonous to humans. Swallowing gasoline or breathing in its vapors can lead to serious health issues.
• Obtain clear tubing that is 1 inch (2.5 cm) in diameter and a closed gas container. Clear tubing is crucial for this method so that you can see the gas moving through the tube and remove it from your mouth before gas reaches it.
• Feed one end of the tubing into the vehicle's gas tank, placing it deep enough so that it sits below the surface of the gas.
• Place the free end of the tubing in your mouth and suck on it, watching the gas flow into the tube. Keep your fingers around the tubing near your mouth so you can crimp it before gas enters your mouth.
• When the gas is about six inches from your mouth, crimp the tubing tightly and remove it from your mouth.
• Check for air bubbles in the tubing. If there are air bubbles, release the crimp and drain the gas back into the car, then try again.
• Stick the end of the tubing into the gas can and release your crimp. The gas should begin to flow into the can, and gravity will pull the rest of the gasoline from the tank.
• Pull the tubing up out of the tank when you have nearly reached the desired amount of gas to stop the flow. Alternatively, cover the free end of the tubing and lift it higher than the level of gas in the tank to make the gas flow back into the tank.
• Remove the tubing from the gas container once all the gas has flowed out.

Note: It is important to consult your vehicle's manual or seek advice from a trusted mechanic before attempting to siphon gas, as there may be specific considerations or precautions for your particular model.

Using a car jack and stands

If you are removing the fuel tank to access the fuel pump in your Ford F-150 or Super Duty, you will need to siphon the gas and use a car jack and several stands. You will also be spending a lot of time underneath your vehicle and you will need to remove all lines that connect the fuel tank to the truck itself.

Step 1: Remove fuel from your tank

Before removing your fuel tank, you will need to siphon the gas out using a clear hose and air pump.

Step 2: Elevate your truck

Use a standard jack and place it in the grooves along the frame of your truck. For trucks that are already lifted, you may have enough room to work without having to jack up your truck. In order to safely work beneath your F-150, your vehicle will need to be propped at least 18 inches above the ground.

Step 3: Remove the heat shield

Once your truck is safely and securely raised, grab your impact wrench and crawl under the truck. You will find that the heat shield is protecting the fuel pump. You will also notice two sets of bolts. One set holds the heat shield in place. The second set holds the fuel tank in place. You first want to locate those that hold the heat shield. They will be aligned with the heat shield strap. Be careful not to remove the bolts for the tank straps before removing the heat shield. After removing the bolts, the heat shield will start to drop as you remove it. Place your knee against it so it doesn't fall on you as you wiggle it free. Once it is free, put it aside.

Step 4: Remove fuel tank

Grab two floor jacks and place them underneath the fuel tank. You will need these to support the fuel tank as you remove its bolts. Be sure that the jacks are raised just enough to support the tank. It's also a good idea to insert some soft padding between the jack stand and the tank to prevent damage. Once again use your impact wrench to remove the four exceptionally long bolts (13mm) from the fuel tank. Once both straps are loosened, lower the straps and twist them off. Don't force them or you will wind up ruining the mounting point. Set the two straps and the bolts to the side.

Now your fuel tank should be supported only by the jack stands. Ask somebody to slowly lower the stands while you hold the fuel tank. The front end won't drop right away because it is connected to the fuel fill line. You will need a 1/4 inch hex socket to remove this connection. Once the fuel fill line is disconnected, your assistant can lower the jack stands further and you should be able to pull the fuel tank out from under the truck.

Removing lines connecting the tank to the truck

To remove the lines connecting the tank to the truck, first ensure that your Ford F-150 or Super Duty is on a flat and safe surface with the engine off. This task will require you to spend a lot of time underneath your vehicle, so it is important to be safe and prepared. You will need to remove all lines that connect the fuel tank to the truck, and some of these connections may be very rusty and tough to loosen.

Begin by siphoning the gas out of your tank using a clear hose and an air pump. Make sure the tank is empty or close to empty before proceeding. Next, elevate your truck using a car jack. Place the jack in the groves along the frame of your truck and raise it at least 18 inches above the ground. If your truck is already lifted, you may have enough room to work without jacking it up.

Now, grab your impact wrench and crawl under the truck to locate the heat shield. The heat shield is protecting the fuel pump and you will also notice two sets of bolts—one set holds the heat shield in place, and the other set holds the fuel tank in place. Be careful to only remove the bolts for the heat shield, which will be aligned with the heat shield strap. After removing these bolts, the heat shield will start to drop, so place your knee against it to prevent it from falling on you as you wiggle it free. Once it is removed, set it aside.

At this point, grab two floor jacks and place them underneath the fuel tank to support it as you remove its bolts. Raise the jacks just enough to support the tank and insert some soft padding between the jack stand and the tank to prevent damage. Now, use your impact wrench to remove the four long bolts from the fuel tank. Once both straps are loosened, lower and twist them off gently, being careful not to force them and ruin the mounting point. Set the straps and bolts aside.

With the jacks now supporting the fuel tank, ask a helper to slowly lower the stands while you hold the fuel tank. The front end of the tank won't drop right away because it is connected to the fuel fill line, which you will need to disconnect using a 1/4 inch hex socket. Once the fuel fill line is disconnected, your assistant can lower the jack stands further and you should be able to pull the fuel tank out from under the truck.

Removing the heat shield

Now that you've safely raised your Ford F-150 or Super Duty truck, you're ready to remove the heat shield. Crawl under the truck and locate the heat shield, which is protecting the fuel pump. You will notice two sets of bolts. The first set holds the heat shield in place, while the second set secures the fuel tank.

To remove the heat shield, first identify the bolts that hold it in place. These will be aligned with the heat shield strap. Use an impact wrench to remove these bolts. Be careful not to remove the bolts for the tank straps by mistake.

Once the bolts are removed, the heat shield will start to drop. Place your knee against it to prevent it from falling on you as you wiggle it free. After it is free, set it aside.

Supporting the fuel tank

The next step is to support the fuel tank as you remove its bolts. Place two floor jacks underneath the fuel tank and raise them just enough to support the tank. It's recommended to place some soft padding between the jack stand and the tank to avoid any damage.

Removing the fuel tank

Now, use your impact wrench again to remove the four long bolts (13mm) from the fuel tank. Once both straps are loosened, carefully lower and twist them off. Avoid forcing them, as this may damage the mounting point. Set the straps and bolts aside.

At this point, the fuel tank should only be supported by the jack stands. Ask an assistant to slowly lower the stands while you hold the fuel tank. The front end won't drop immediately because it's connected to the fuel fill line, which can be disconnected using a 1/4 inch hex socket.

With the fuel fill line disconnected, your assistant can continue to lower the jack stands, allowing you to pull the fuel tank out from under the truck.

Removing the fuel tank

This step requires siphoning gas and using a car jack and several stands. You will also be spending a lot of time underneath your vehicle and you will need to remove all lines that connect the fuel tank to the Ford F-150 or Super Duty truck itself. The biggest difficulty with this option is that some of the connections might be very rusty and tough to loosen.

Step 1: Remove fuel from your tank

Before removing your fuel tank, you will need to be sure it is empty, or close to empty. In order to do this, you will need to siphon the gas out using a clear hose and air pump.

Step 2: Elevate your truck

In order to safely work beneath your F-150, your vehicle will need to be propped at least 18 inches above the ground. Use a standard jack and place it in the grooves along the frame of your truck. For trucks that are already lifted, you may have enough room to work without having to jack up your truck.

Step 3: Remove the heat shield

Once your truck is safely and securely raised, grab your impact wrench and crawl under the truck. You will find that the heat shield is protecting the fuel pump. You will also notice two sets of bolts. One set holds the heat shield in place. The second set holds the fuel tank in place. You first want to locate those that hold the heat shield. They will be aligned with the heat shield strap. Be careful not to remove the bolts for the tank straps before removing the heat shield. After removing the bolts, the heat shield will start to drop as you remove it. Place your knee against it so it doesn't fall on you as you wiggle it free. Once it is free, put it aside.

Step 4: Remove the fuel tank

Grab two floor jacks and place them underneath the fuel tank. You will need these to support the fuel tank as you remove its bolts. Be sure that the jacks are raised just enough to support the tank. It's also a good idea to insert some soft padding between the jack stand and the tank to prevent damage. Once again, use your impact wrench to remove the four exceptionally long bolts (13mm) from the fuel tank. Once both straps are loosened, lower the straps and twist them off. Don't force them or you will wind up ruining the mounting point. Set the two straps and the bolts to the side. Now your fuel tank should be supported only by the jack stands. Ask somebody to slowly lower the stands while you hold the fuel tank. The front end won't drop right away because it is connected to the fuel fill line. You will need a 1/4 inch hex socket to remove this connection. Once the fuel fill line is disconnected, your assistant can lower the jack stands further and you should be able to pull the fuel tank out from under the truck.

Frequently asked questions