Regan Brown
Dropping the fuel tank of a Ford F-150 is a complex process that requires careful execution. It is essential to ensure that the fuel tank is almost empty before beginning the procedure. The use of a floor jack with a balancing support structure is recommended to lower and lift the tank safely. Removing bolts, lowering the tank, loosening hose clamps, disconnecting wiring harnesses, and fuel line connections are critical steps in this process. Additionally, the fuel pump and its components, such as the retention ring, hoses, and wiring harness, may require modifications or replacements. Safety precautions and mechanical expertise are crucial when performing this task.
Characteristics and Values Table for Dropping Fuel Tank in F150
| Characteristics | Values |
|---|---|
| Fuel Tank Removal | Ensure the tank is almost empty, use a floor jack to balance the tank, remove bolts, lower the tank, loosen the hose clamp, disconnect wiring and fuel line connections, and pull out the tank |
| Fuel Pump Replacement | Modify the pump basket to accommodate the new pump, secure the wiring harness, and ensure proper fitment of the filter screen |
| Rust and Strap Considerations | Rusted bolts and clips may require grinding, consider replacing straps if cutting or unbolting is difficult |
| Alternative Methods | Option to pull the bed instead of dropping the tank, especially if fuel pump failed with a full tank or bolts are rusted |
| Tools | Floor jack, cutters, punch, dead blow hammer, transmission jack |
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What You'll Learn
Ensure the tank is almost empty before lowering it
It is important to ensure that the fuel tank of your F-150 is almost empty before lowering it. This is because fuel can be hazardous and heavy, and a full tank can pose safety risks and make the process more difficult.
Firstly, a full tank of fuel is extremely heavy, and lowering a heavy tank can be more challenging and dangerous. The process of dropping the tank involves various steps, such as balancing, lowering, and removing bolts and connections. Attempting to do this with a full tank adds significant weight and can make the process more cumbersome and time-consuming.
Secondly, fuel is a flammable substance, and working with a full tank can increase the risk of fire or explosion. When lowering the tank, it is crucial to avoid any potential sources of ignition or sparks. By ensuring the tank is almost empty, you reduce the amount of fuel vapour present, decreasing the chances of an accidental fire or explosion.
Additionally, driving with a full tank of fuel can be detrimental to your vehicle's fuel pump and engine. The fuel pump is designed to remain submerged in fuel, and when the tank is consistently low, the pump can become damaged from being over-stressed and overheated. This can lead to costly repairs or replacements.
Furthermore, fuel shortages or supply issues can impact your ability to refill the tank once it is lowered. By ensuring the tank is almost empty before starting the process, you reduce the risk of being caught off guard by fuel shortages and having a partially lowered tank with no immediate means to refill it.
In conclusion, ensuring that the fuel tank of your F-150 is almost empty before lowering it is a crucial safety precaution. It makes the process easier and safer by reducing weight and potential fire hazards. Additionally, it helps maintain the health of your vehicle's fuel pump and engine and ensures you are not caught off guard by fuel supply issues. Always follow proper safety protocols and refer to reliable sources for specific instructions on dropping the fuel tank of your F-150.
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Use a floor jack to balance the tank
To drop the fuel tank of an F-150, you can use a floor jack to balance the tank. This is a stable method, although it can be costly and take up more space than other options. A floor jack is also easier to use than a bottle jack, which is more compact but less stable.
When using a floor jack, it is important to ensure that the tank is almost empty, as a full tank will be too heavy and could be dangerous. You can also use a piece of wood, such as plywood, or nylon ratchet straps to help balance the tank on the jack.
To begin, loosen the bolts on the tank and slide the jack underneath. Place the saddle of the jack just forward of the slope up in the skid plate, then balance the tank on the jack. You can then lower the tank slowly and disconnect the tubes and fuel lines.
It is helpful to have an assistant to hold the rear end of the tank while you let the jack down in the front. With this method, you can work on the tank while it is still supported by the jack. Once you have finished your repairs or replacements, you can then jack the tank back up, reconnect the tubes and fuel lines, and secure the bolts.
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Remove bolts on the frame side of the tank
To remove the bolts on the frame side of the tank of your Ford F-150, first ensure that the tank is almost empty. Use a floor jack with a 3' 2x10 on top to balance the tank as it is lowered and lifted. There are two bolts on the frame side of the tank that need to be removed to lower the tank a few inches. If these bolts are rusted or difficult to access, you may need to use a grinder to remove them.
Once the bolts are removed, you can lower the tank a few inches. Next, loosen the hose clamp for the fuel fill hose and drop the tank. Detach the wiring harness and fuel line connections before pulling the tank out from under the truck.
If you encounter any broken or spinning bolts, there are a few options to address them. You can put the other bolts back in and attempt to pull the box off, or you may need to cut the straps and replace them. Drilling or grinding the bolt off is another option to remove stubborn bolts.
It is important to have assistance when lowering and lifting the fuel tank, especially if you are using a jack or hoist to support the weight of the tank. Ensure that you have the necessary tools and equipment to safely balance and lower the tank.
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$14.99
Loosen the hose clamp and remove wiring harness
To loosen the hose clamp and remove the wiring harness, you will need to follow a few steps. First, you need to disconnect the fuel tank filler hose vent tube quick-connect fitting from the top of the fuel pump module. This will involve prying the hose clamp to loosen it and then removing the filler hose. You can use a screwdriver or a non-metal chisel/punch for this step. Be sure to also disconnect the electrical connectors from the fuel pump module and EVAP sensors.
Next, you will need to lower the tank to unplug any wire harness brackets or vapor lines that may be difficult to reach when the tank is in the vehicle. Use a jack to slowly lower the tank while steadying it to ensure it doesn't fall. Once the tank is lowered, you can then remove the wire harness by pulling on the connectors until they come loose. Be careful to wear eye protection as dirt may fall during this step.
If you are removing the truck bed instead of the fuel tank, the process is slightly different. You will need to slide underneath the truck bed and locate the wire harness for the bed lighting in the left rear corner. Pull on the connectors to disconnect the wiring harness and let them hang loose. Then, you will need to remove the taillight plugs by twisting and pulling them out.
Finally, if you are dealing with a 1990 F-150, there are specific considerations to keep in mind. The fuel tank has four hoses and an electrical connector attached. The pressure and return hoses connect at the sending unit, along with the 4-wire electrical connector. To remove the filler hose, start by removing the three screws around the filler orifice inside the fuel door. Then, loosen the right clamp under the truck, sliding it off the mounting ear. Repeat this process for the left clamp, sliding it up the filler body. Now, you can pull the filler away from the filler hose. Remember to use safety glasses as you gently work each hose free, as some residual gas will leak out.
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Pull the tank out and remove the lock ring
To pull out the fuel tank and remove the lock ring, you will first need to remove the fuel tank. It is recommended that you ensure the tank is almost empty before attempting this. You can use a floor jack with a 3' 2x10 on top to help balance the tank as it is lowered and lifted. Remove the two bolts on the frame side of the tank, then lower the tank a few inches. Loosen the hose clamp for the fuel fill hose and drop the tank. Take off the wiring harness and fuel line connections, then pull the tank out from under the truck.
Now that the fuel tank has been removed, you can proceed to remove the lock ring. This can be done using a punch and a dead blow hammer to knock it loose. Turn the fuel pump locking retainer ring counterclockwise with a Fuel Tank Sender Wrench D84P-9275-A or an equivalent tool (a brass punch is preferred). Remove the fuel pump locking retainer ring, then take out the fuel tank sending unit and pump from the fuel tank.
Some people choose to soak the lock ring in PB blaster for several days before removal to help loosen it. Others suggest using an air hammer or an air needler to break up chunks and relieve stress on the ring. If you are concerned about creating sparks, you can cover the tip of your tool with a shop rag or epoxy before hammering.
Once the lock ring is removed, you can proceed with any necessary maintenance or repairs. Remember to exercise caution when working with fuel system components and always refer to a qualified mechanic if you are unsure about any steps.
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Frequently asked questions
Ensure the tank is almost empty. Use a floor jack with a 3' 2x10 on top to balance the tank as it is lowered and lifted. Remove the two bolts on the frame side of the tank and lower the tank a few inches. Loosen the hose clamp for the fuel fill hose and drop the tank.
If the bolts are rusted solid to the clips, you may need to grind or drill the bolt off.
It is possible to drop the tank without removing the bed. However, some people prefer to remove the bed if they have the equipment to do so, as it can make the process easier.
If the screw closest to the bumper breaks, you can try putting the other bolts back in and pulling the box off. Or, you can cut the straps and replace them.
