Katerina Swanson
The 1994 F-150 is a truck with a dual gas tank setup. While some users have reported issues with the front tank, such as overfilling and gas going all over the place, others have experienced problems with the rear tank leaking. If you are looking to remove the side fuel tank on your 1994 F-150, it is important to note that there are two different designs for the fuel pump system. In one design, the rear tank pumps fuel to the front tank, while in the other design, the rear tank pumps fuel directly to the engine. If your truck has the former design, you would need to re-do the fuel lines to bypass the front tank. Additionally, if you choose to remove the rear tank, you must join the two rear lines together.
| Characteristics | Values |
|---|---|
| Removing the side fuel tank | Disconnect the 2 fuel hoses going to the tank and then plug them individually |
| Disconnect the electrical connector to the front fuel pump | |
| Disconnect the rear fuel pump | |
| Remove the selector switch and wire the rear to an on-off toggle switch | |
| Clamp off the front 2 lines to the 6-port POS selector fuel reserve | |
| Remove the rear gas tank | |
| Remove the fuel splitter | |
| Connect the front tank fuel line to the fuel filter | |
| Leave the switch on the dashboard for the front fuel tank | |
| Advantages of having a dual fuel tank | If one pump quits, you can switch to the other tank |
| Disadvantages of having a dual fuel tank | Unbalanced weight distribution |
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What You'll Learn
Removing the rear fuel tank
Step 1: Safety First
Before starting any work on your vehicle, it is important to ensure your safety. Make sure the vehicle is parked on a level surface, engage the parking brake, and block the front and rear wheels to prevent accidental movement. Wear protective gear, including gloves and eye protection, to shield yourself from debris and fluids.
Step 2: Drain the Fuel Tank
Start by draining the rear fuel tank completely to make it lighter and easier to handle. You can do this by siphoning the fuel into an approved container or running the vehicle until the rear tank is empty. Be extremely cautious when handling flammable liquids, and ensure proper ventilation in your workspace.
Step 3: Disconnect the Fuel Lines
Locate the fuel lines connected to the rear tank. Carefully disconnect these lines, making sure to plug or cap the openings to prevent fuel leakage and minimize the risk of fire. You may need specialized tools, such as fuel line disconnectors, to detach the lines safely.
Step 4: Remove the Fuel Pump
The fuel pump is typically located within the fuel tank or close to it. Disconnect the electrical connector to the fuel pump and any other associated wiring. You may need to remove bolts or clamps securing the fuel pump in place before carefully lifting it out.
Step 5: Detach the Fuel Tank Straps
The fuel tank is usually held in place by metal straps or brackets. Using the appropriate tools, such as a socket wrench or a screwdriver, loosen and remove these straps to release the fuel tank. Be cautious not to drop the tank suddenly, as it may be heavy and cause injury or damage.
Step 6: Lower and Remove the Fuel Tank
With the straps removed, carefully lower the fuel tank from the vehicle. This step may require assistance, as the tank can be cumbersome. Once the tank is clear of the vehicle, set it aside in a safe location, ensuring it is securely supported to avoid accidental spills.
Step 7: Address the Fuel Lines
After removing the rear fuel tank, you must join the two rear fuel lines together to bypass the eliminated tank. This step is crucial to ensuring the proper functioning of the remaining fuel system. Consult a mechanic or a professional if you are unsure about this process.
Step 8: Clean-up and Inspection
Clean the area where the rear fuel tank was located, inspecting for any signs of damage, corrosion, or leaks. Ensure that all fuel lines, connections, and components are secure and properly routed. Verify that the remaining fuel system, including the front tank and associated hardware, is in good working order.
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Disconnecting the fuel hoses
Firstly, locate the fuel hoses connected to the tank. There should be two fuel hoses: one coming out of the fuel pump and the other being the return fuel hose going back to the tank. It is important to identify these correctly to ensure a proper disconnection.
Now, for the disconnection process, there are a few methods that can be used. One common method is to use a quick-connect removal tool. This tool is designed to be inserted inside the fitting, and with a gentle push, it will help pop off the fuel line connections. This is a safe method to ensure that the connectors are not damaged during the removal process.
Another method, as suggested by a user, involves using a short piece of plastic tube. Find a small plastic tube, like the type used for a DVD spindle, and cut it open along its length. Place this plastic tube around the gas line, and then slide it inside the connection. With one quick motion, slide the connection and the tube off the fitting simultaneously. This innovative method can be useful if you do not have access to a specialised tool.
If you are unable to obtain either of these tools, there is a more rudimentary method that involves using pliers. With caution, you can use pliers to break the tubes off the fuel pump. However, this method may not be suitable for everyone as it requires more force and carries a higher risk of damage. After breaking the tubes, it is crucial to cap the tubes securely with a rubber hose and hose clamps to prevent any leaks.
Additionally, it is important to note that there may be electrical connectors involved, as seen in some models of the F150. Ensure that you disconnect any electrical connectors associated with the fuel pump.
By following these steps and choosing the most suitable method for your situation, you can successfully disconnect the fuel hoses when removing the side fuel tank of your 1994 F150.
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Plugging the fuel lines
There is a neat trick to disconnecting the lines, which involves using a short piece of plastic tube that is open at both ends. Cut the tube down the middle, lengthways, so that it can fit around the gas line. Pull the fuel line connection side away, slide the plastic tube inside the connection, and then push the connection towards the tube, ensuring the tubing does not move. With one motion, slide the connection and tube off the fitting together.
Once the fuel lines are disconnected, they need to be plugged. One method is to ball up a clean rag and pop it into the end of the line. This is not a long-term solution, but it will work in the short term. Another method is to use rubber hoses, bolts, and hose clamps to cap the lines.
It is important to note that some people recommend against connecting the fuel lines together, as this could create a direct connection between the high-pressure and low-pressure sides of the fuel system. Instead, it is recommended to plug each line individually.
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Replacing the fuel pump
To replace the fuel pump in a 1994 F150, you will first need to remove the fuel tank. It is recommended to remove the bed of the truck as well, as this will make it easier to access both tanks.
Once you have removed the fuel tank, you can begin installing the new fuel pump. First, apply a light coating of Premium Long-Life Grease XG-1-C or -K, or an equivalent meeting Ford specification ESA-M1C75-B, on a new fuel pump mounting gasket to hold it in place during assembly. Install it in the fuel ring groove.
Next, install the fuel tank sending unit and pump carefully, ensuring that the fuel filter is not damaged. Make sure that the tabs of the fuel tank sending unit and pump are positioned into the slots of the fuel tank, and that the ring remains in place.
Hold the fuel tank sending unit, pump, and fuel pump mounting gasket in place, and install and rotate the fuel pump locking retainer ring clockwise until the stop is against the retainer ring tab.
Finally, reinstall the fuel tank and bed of the truck, if removed.
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Removing the fuel injector wiring harness
To remove the fuel injector wiring harness from a 1994 F-150, you will first need to remove the fuel injectors from the fuel rail. This can be a tricky process, as the wires and fuel rail are tightly crammed into a small space.
Firstly, ensure that you have removed all the plugs from the injectors. This can be done using an Allen wrench to depress the clip, and a flat screwdriver to pry at the same time. Once all the plugs are removed, you can then take out the wiring harness from the rail.
You may need to wiggle the rails out, and it may be necessary to unclip the harness from both rails, moving one out of the way to wiggle the other past. It is also important to note that the wires all feed to the large square connector in the centre, so you will need to back out the bolt in the centre and pull the engine side off.
In some cases, it may be necessary to replace the whole engine harness.
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Frequently asked questions
Removing the side fuel tank from your 1994 F150 can be done in several ways. One method is to disconnect the two fuel hoses going to the tank and then plug them individually, as well as disconnecting the electrical connector to the fuel pump.
Some common issues with the fuel tank of the 1994 F150 include overfilling, leaking, and fuel transferring to the wrong tank.
Solutions to issues with the fuel tank of the 1994 F150 include replacing the tank, fixing fuel lines, or converting the truck to use a single tank.
