Katerina Swanson
The Ford F-150 is a truck with the option of a dual-tank fuel system, which allows drivers to switch between tanks while driving. However, some owners of the F-150 have reported issues with the dual-tank setup, such as leaks, fuel being drawn from the wrong tank, and problems with the transfer valve. Some have considered removing one of the tanks, but this could affect weight distribution and storage space for the spare tire. While it is technically possible to remove a fuel tank, it is a complex process that requires careful consideration and planning.
| Characteristics | Values |
|---|---|
| Vehicle Type | Ford F-150 |
| Vehicle Model Year | 1984-1996 |
| Fuel Tank Configuration | Dual tanks (rear and front) |
| Issue | Rear tank leaking, fuel transferring to the rear tank |
| Solution | Remove rear tank, join two rear lines together, unplug rear fuel pump |
| Alternative Solution | Replace the faulty tank with a new assembly |
| Considerations | Weight distribution, spare tire storage, pump replacement, switch deletion |
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What You'll Learn
Removing the rear tank and fuel splitter
Firstly, it is important to address the issue of fuel transfer between the front and rear tanks. Some users have reported that their rear tank leaks, and when they fill the front tank, the fuel ends up in the rear tank. To resolve this, unplug the wires connected to the rear fuel pump to prevent it from drawing fuel. You can also consult your local Ford dealership, as there was a recall for this issue.
Next, the rear tank and the fuel lines connected to the fuel splitter can be removed. Be cautious when handling the fuel lines, as some users have reported them being rusty and difficult to disconnect. One approach is to use pliers to break the tubes off the fuel pump and then cap the tubes with rubber hoses and hose clamps. Ensure that all relevant tubes, such as the breather tube, are capped appropriately.
After removing the rear tank, you must join the two rear lines together. This step is crucial to ensure the safe and proper functioning of the remaining fuel system.
Finally, connect the front tank's fuel line directly to the fuel filter, bypassing the fuel splitter. Leave the switch on the dashboard for the front fuel tank intact.
It is important to note that removing the rear tank may affect weight distribution and the storage position of the spare tire. Additionally, some users have mentioned concerns about the switch being accidentally swapped, so consider this before deciding to remove the rear tank and fuel splitter of your Ford F-150.
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Capping off lines to prevent fuel transfer
Capping off lines is a simple way to prevent fuel transfer from the front tank to the rear tank in a Ford F-150. This method does not require rewiring or rerouting lines and can be done without completely removing the tanks.
One way to cap off the lines is to use pliers to break the tubes off of the fuel pump and then cap the tubes with a rubber hose, a bolt, and hose clamps. This method was used by an F-150 owner who reported that their truck ran great and the gauge worked perfectly after the procedure, with no more gas leaks.
Another method to cap off the lines is to use rosin core solder. Heat the solder into the in and outlets, and then plug the vacuum lines. This method is simple and easily reversible, according to an F-150 owner.
It is important to note that when capping off the lines, you must also cap off the breather tube to prevent any issues with tank pressure. Additionally, make sure to disconnect and secure any wire connectors to the frame.
If you are planning to remove the rear tank, it is recommended to join the two rear lines together to prevent any issues.
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Replacing the transfer on the left side of the frame
To replace the transfer on the left side of the frame of your F150, you will first need to remove the rear fuel tank. This can be done by blocking off all lines and tying them up onto the frame of the truck, as mentioned by one user. Another user recommends dropping the rear tank, though this can be a challenge due to the limited length of the lines. Instead of disconnecting the rusty lines, you can use pliers to break the tubes off the fuel pump and cap the tubes with a rubber hose and hose clamps.
Once the rear tank is removed, you can access the fuel transfer components on the left side of the frame. The fuel switching valve is located on the side of the frame rail and can be replaced by following the instructions and diagrams provided in the source material.
It is important to note that some users have reported issues with fuel transferring from the rear tank to the front tank even after replacing the transfer on the left side of the frame. One user suggested that this could be due to a faulty shuttle selector valve, but they were unable to find a solution.
To prevent fuel transfer issues, one user recommended leaving the selector valve and associated wiring intact, and simply removing and rerouting the fuel lines. This approach avoids the need for rewiring or rerouting of lines and has been reported to work well.
Another user shared their experience of removing the rear tank and fuel lines and capping the switch valve. They inquired about completely removing the valve and running the lines directly to the engine, but were concerned about the impact on the fuel sending unit's ability to register fuel levels. Unfortunately, there is no clear resolution provided in the source material.
When replacing the transfer on the left side of the frame, it is important to consider the specific model and configuration of your F150, as different models may have variations in the fuel delivery system. Some models have a single tank with a single fuel pump or a single tank with a Fuel Delivery Assembly (FDA), while others have dual tanks, each with its own FDA. Understanding your vehicle's specific setup will help ensure a successful transfer replacement.
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Replacing the rear fuel pump
Before attempting to replace the rear fuel pump on your Ford F-150, it is important to confirm that the fuel pump is faulty. Symptoms of a failing fuel pump include hard starts and a loss of power while towing or driving uphill. If the pump is bad, it will need to be replaced as soon as possible.
Preparation
Firstly, ensure your F-150 is on a flat and safe surface, with the engine off. Next, siphon the gas from the tank using a clear hose and an air pump. This step is necessary before removing the fuel tank. Be sure to store the fuel in a safe container.
Removing the Fuel Tank
You will need to remove the fuel tank or the truck bed to access the fuel pump. To remove the fuel tank, start by removing the bolts holding the tank in place, as well as the two straps. Gently twist them off to avoid damaging the mounting point. Now, carefully lower the floor jacks while holding the fuel tank. It is much easier to have an assistant help you with this step. About halfway through, disconnect the fuel fill line using a 1/4 inch hex socket.
Accessing the Fuel Pump
With the fuel tank disconnected, you can now access the fuel pump module, which is bolted to the top of the fuel tank. The fuel lines are connected to the module by safety clips. You can pull and release them or use a 3/8” Ford fuel line disconnect tool. Clean off any dust and dirt from the top of the fuel pump module using a plastic brush. This will help prevent the fuel tank from getting contaminated when you remove the old fuel pump assembly.
Replacing the Fuel Pump
Unfasten the bolts holding the fuel pump module onto the fuel tank. Twist the old fuel pump assembly out of the tank. You can now install the new fuel pump assembly. Be sure to also replace the fuel tank gasket and the sock strainer that goes over the bottom of the fuel pump housing. Finally, reconnect the fuel lines, ensuring they are secure.
Reinstalling the Fuel Tank
To reinstall the fuel tank, simply reverse the removal process. Ensure all connections are secure before moving on to the next step. Once the fuel tank is securely in place, you can refill the tank with the fuel that was siphoned earlier.
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Replacing the tank with a new assembly
If you're looking to replace your F150 rear fuel tank with a new assembly, there are a few things you should keep in mind. Firstly, it's important to address the reason for the replacement. In many cases, people choose to replace their rear fuel tank due to leaks or fuel transfer problems between the front and rear tanks.
Before beginning the replacement process, it's recommended to consult your local Ford dealership, especially if your vehicle is under recall for fuel transfer issues. They can provide specific advice and parts tailored to your truck's needs.
Now, let's get into the replacement process. Firstly, you'll need to safely remove the rear fuel tank. This can be a challenging task, as some have experienced issues with the lines not being long enough to drop the tank to the ground. One approach is to use pliers to break the tubes off the fuel pump and then cap the tubes securely with a rubber hose, a bolt, and hose clamps. Don't forget to cap both fuel lines and the breather tube as well.
Once the old tank is removed, you can start the installation of the new tank assembly. You can purchase a replacement tank with all the necessary pumps included for around $200 from suppliers like Spectra. This option is often simpler and more cost-effective than attempting to repair or modify your existing tank.
When installing the new tank, ensure that you follow the manufacturer's instructions and industry safety standards. Pay close attention to the fuel lines and make sure they are securely connected to prevent leaks. Depending on your specific F150 model, you may need to join the two rear lines together as part of the installation process.
Lastly, always perform a thorough inspection and testing of your new tank assembly before considering the job complete. Check for any signs of leaks or fuel transfer issues, and ensure that all hoses, clamps, and connections are secure and in good condition. By following these steps, you can confidently replace your F150's rear fuel tank with a new assembly, improving the reliability and performance of your vehicle.
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Frequently asked questions
Removing the rear fuel tank from a Ford F-150 involves the following steps: disconnecting the fuel lines, capping off the lines to prevent fuel leakage, and ensuring that the spare tire is relocated as it is usually stored against the bottom of the rear tank.
Removing the rear fuel tank can improve weight distribution and reduce the amount of fuel carried. It can also address issues with fuel leaks and transfer problems between the dual tanks.
Yes, instead of removing the tank, you can choose to repair or replace it. This may involve replacing the fuel pump, fixing the transfer valve, or soldering the in and outlets to seal off the tank temporarily.
