Replacing Ford Ranger Fuel Filler Neck: Step-By-Step Guide

If you own a Ford Ranger and are experiencing a fuel tank filler neck leak, you may need to replace the fuel filler neck. This process involves removing the truck bed, which can be done by disconnecting the tail lights near the bumper and removing the hardware in the gas door. It is recommended to replace the truck bed hardware as they are likely corroded. You can then lift the bed, secure it, and remove the filler neck for replacement. When choosing a replacement filler neck, ensure that you do not opt for the cheapest option as these may crack easily.

Removing the bed

First, disconnect the tail lights near the bumper. You will need a fairly large torx bit, such as a T-55, for this step. Next, remove the hardware in the gas door. It is recommended to replace the truck bed hardware as they are likely corroded and will be challenging to remove. To make this process easier, soak them with PB Blaster for a few days.

Once the hardware is removed, you can start lifting the bed. Secure it in a lifted position. If you have access to an engine hoist with a leveller, use that to lift the bed. Alternatively, you can use a tractor loader, but be cautious to avoid banging the cab.

At this point, you can proceed to remove the filler neck and replace it with a new one. Ensure that you purchase a high-quality replacement part to avoid future issues.

Reinstalling the bed would follow the same process but in reverse order. Make sure to double-check all connections and hardware to ensure a secure fit.

Disconnecting the tail lights

Before beginning any work on your vehicle, it is important to ensure your safety. Put on the necessary protective gear, such as gloves and eye protection, and identify a suitable, well-ventilated work area.

Locate the tail lights: The tail lights are positioned near the rear bumper of your Ford Ranger. To access them, you may need to open the tailgate or trunk.

Prepare the work area: Ensure that you have all the necessary tools and equipment within easy reach. This may include screwdrivers, wrenches, or other specialized tools required for your specific vehicle model.

Disconnect the tail light wiring: Before disconnecting the tail lights, make sure you have the correct diagram or manual for your Ford Ranger model. Identify the wiring harness or connector that supplies power to the tail lights. Carefully disconnect the wiring harness by gently pulling or using the appropriate tool. Some connectors may have a release mechanism that needs to be pressed or lifted to detach the connector from the tail light assembly.

Remove the tail light assembly: Once the wiring is disconnected, you can proceed to remove the tail light assembly. This process may vary depending on your Ford Ranger model. Typically, you will need to remove any screws, bolts, or fasteners securing the tail light assembly in place. Use the appropriate tool to carefully loosen and remove these fasteners. Be gentle to avoid damaging the surrounding body panels or the tail light assembly itself.

Store the tail light assembly safely: After removing the tail light assembly, place it in a safe location, away from direct sunlight or moisture. You may want to cover it with a soft cloth or place it in a protective case to avoid scratches or damage during the rest of the repair process.

At this point, with the tail lights disconnected and the assembly removed, you can continue with the next steps of the fuel filler neck replacement process, as outlined in other guides or repair manuals. Remember to work carefully and refer to specific instructions for your Ford Ranger model to ensure a safe and successful repair.

It is important to note that working on your vehicle's fuel system can be dangerous, and it is always recommended to have a qualified mechanic or technician perform these types of repairs if you are unsure or uncomfortable with any part of the process.

Removing hardware in the gas door

To remove the hardware in the gas door of a Ford Ranger, you will first need to disconnect the tail lights near the bumper. Once these are disconnected, you can then remove the hardware in the gas door. It is recommended to replace the truck bed hardware as they are likely to be corroded and difficult to remove. To make this process easier, you can soak them with PB Blaster for a few days.

Soaking hardware in PB Blaster

To replace a fuel filler neck on a Ford Ranger, you'll need to remove the truck bed. This involves removing six bolts, disconnecting the tail lights near the bumper, and removing the hardware in the gas door.

The hardware in the gas door is likely to be corroded, so it's recommended to soak them with PB Blaster for a few days before attempting to remove them. PB Blaster is a penetrating lubricant that can help to loosen rusted or stuck parts. Soaking the hardware will make them easier to remove and reduce the risk of damage.

While PB Blaster can be effective, it may not work on all types of build-up. Some users have reported that it did not work for them, even after soaking for several hours or days. The effectiveness of PB Blaster may vary depending on the specific application and the type of build-up or corrosion present. It's important to note that PB Blaster should not be used as a substitute for recommended cleaning solutions or maintenance procedures. Always refer to the manufacturer's instructions or seek advice from a qualified mechanic.

When soaking hardware in PB Blaster, it's important to allow sufficient time for the product to penetrate and loosen the corrosion. The soaking time may vary depending on the severity of the corrosion and the specific application. In some cases, a few hours may be sufficient, while other cases may require a few days of soaking. It's important to follow the instructions on the PB Blaster product label and exercise patience during the soaking process.

During the soaking process, it's recommended to place the hardware in a container that can be sealed or closed tightly. This will help prevent evaporation and ensure that the PB Blaster remains in contact with the hardware for an extended period. Additionally, it's important to work in a well-ventilated area when using PB Blaster and to wear appropriate protective gear, such as gloves and eye protection.

Replacing the truck bed hardware

To replace the truck bed hardware on your Ford Ranger, you'll first need to remove the existing truck bed. This involves disconnecting the tail lights near the bumper and removing the hardware in the gas door. It is recommended to soak the hardware with PB Blaster for a few days beforehand to help remove any corrosion.

Once the truck bed is removed, you can install the new bed. Ensure that you have the correct bed for your model of Ford Ranger. For example, a user with a 2008 Ford Ranger in need of a new bed was advised to get a bed from a 1993-2011 model. However, another user with a 2010 Ford Ranger was told that only 2009-2011 bed models would fit. It is always a good idea to bring a tape measure to check bolt locations and drill new holes if needed.

When installing the new truck bed, use a truck bed mounting hardware kit, which includes all the bolts, nuts, and washers necessary to secure the frame. You can purchase these kits from companies like Dorman and Sherman.

Frequently asked questions