Replacing Ford's Easy Fuel Cap: A Step-By-Step Guide

The Ford Easy Fuel capless fuel filler is a convenient feature that eliminates the need for a traditional fuel filler cap. It allows drivers to simply insert the fuel nozzle into the tank, and once fuelling is complete, the spring-loaded fuel filler automatically closes and latches. While this system offers benefits such as preventing splashback, fuel theft, and vapour escape, issues may still arise that require replacement or repair. For example, if the inner flap mechanism is damaged, it may need to be replaced to avoid gas fumes escaping and potential error codes.

Removing the bed of your truck

To remove the bed of your truck, you will need to first remove the mounting bolts, unhook the fuel filler neck, and disconnect the wiring harness. You can then use ratchet straps to lift the bed and drive the truck out from underneath.

• Find all the mounting bolts, fuel filler neck, and wiring. You may need to refer to other threads or a Google search for this step.
• Remove the mounting bolts.
• Unhook the fuel filler neck.
• Disconnect the wiring harness.
• Obtain four good-quality ratchet straps and screw their eyelets into the ceiling joists. Ensure that you screw them into ceiling joists and not just drywall.
• Go around and raise each corner of the bed 3-4 inches at a time. You may need to release and reset the ratchet strap to gain more height.
• Once the bed is high enough that your tires will clear the rocker panels, drive the truck out from underneath the bed. Be careful not to drive over any excess ratchet strap.

Alternatively, you can use a jack to lift the bed in four places and then drive the truck out from underneath. If you don't have a garage, you can use a superstructure made out of 2x4s or cribbing methods to support the bed while you work.

If you are removing the bed to access the fuel filler cap, you can try the following:

• Go under the truck and disconnect the rubber hose from the filler neck.
• Unbolt the filler neck from the frame.
• There may be a clamp of some kind under the bedside fender panel that connects the fuel tank filler hose to the fuel cap opening.

Disconnecting the fuel filler from the body

Firstly, locate the rubber hose connected to the filler neck. This can be found underneath the truck. Once you have located the hose, carefully disconnect it from the filler neck. This will involve some force, but be gentle to avoid causing any damage.

Now, you need to unbolt the filler neck from the frame of the truck. This will require the use of tools to remove the bolts. Make sure you have the correct size tool for the bolts, as you don't want to strip the heads. With the filler neck unbolted, you can now lift and remove the bed of the truck.

At this stage, you will need to locate the clamp that connects the fuel tank filler hose to the fuel cap opening. This clamp should be found under the bedside fender panel. Once you have located this clamp, carefully disconnect the fuel tank filler hose from the fuel cap. This process may vary depending on the model of your Ford truck, so be sure to consult your owner's manual or seek advice from a qualified mechanic if you are unsure.

It is important to note that working on fuel systems can be dangerous, so ensure you take the necessary safety precautions. Always wear protective gear, such as gloves and eye protection, and be cautious of any fuel that may still be in the lines. It is also a good idea to have a fire extinguisher nearby as a safety precaution.

By carefully following these steps, you will be able to successfully disconnect the fuel filler from the body of your Ford truck. Remember to work slowly and carefully, and if you are unsure about any part of the process, don't hesitate to seek professional assistance.

Disconnecting the taillight wiring harness

Firstly, locate the taillight wiring harness. It is likely connected to the taillight, which you can access by removing the tailgate. Be sure to have safety glasses on to avoid dirt dropping into your eyes.

Once you have located the wiring harness, carefully disconnect it from the taillight. You may need to remove the taillight completely by unscrewing the bolts holding it in place. Typically, there are two bolts that need to be removed, and then you can pull the taillight towards the rear of the vehicle to take it out.

After disconnecting the wiring harness, you will need to set it aside safely. Ensure that the wires do not fall back into the vehicle's body, which may require tying them up or securing them with tape.

At this point, you should be able to access the bolts holding the truck bed in place. Be cautious of any fuel lines or other sensitive components while working in this area.

Finally, before proceeding with your L-track installation, make sure to consult a professional mechanic or a detailed guide specific to your Ford model to ensure you don't miss any important steps or safety precautions.

Removing the bed bolts

To remove the bed of your truck, you'll need to remove the bed bolts. Here's a step-by-step guide on how to do this:

Step 1: Locate the Bed Bolts

Start by identifying the bed bolts that need to be removed. These bolts are typically located around the truck's bed, securing it to the frame.

Step 2: Gather the Necessary Tools

Make sure you have the right tools for the job. You will likely need a socket wrench or a ratchet and socket set to remove the bed bolts. It's also a good idea to have some silicone lubricant or anti-seize lubricant on hand to make the process easier.

Step 3: Prepare the Bolts for Removal

Before attempting to remove the bed bolts, it's important to prepare them. Spray the bolts with a penetrating lubricant a day before you plan to remove them. This will help to break down any rust or corrosion that may have built up, making the bolts easier to remove.

Step 4: Start Removing the Bolts

Using your socket wrench or ratchet, begin removing the bed bolts. Work in a systematic manner, removing the bolts one by one. If the bolts are too tight, apply more penetrating lubricant and allow it to soak for a while before trying again. You can also try using a breaker bar with your socket wrench for additional leverage.

Step 5: Clean and Inspect the Bolts

As you remove each bolt, clean it and inspect it for damage or excessive wear. If any of the bolts are damaged or stripped, you may need to replace them with new ones of the same size and grade.

Step 6: Store the Bolts Safely

Once all the bed bolts are removed, store them in a safe place. Keep the bolts together with their corresponding washers and nuts, as you'll need to reinstall them properly when you're done with your project.

Removing the cap around the filler

Firstly, locate the four 7mm bolts that are behind the cap. These bolts secure the cap in place, and you will need to remove them in order to take off the cap. You may need to disconnect the fuel filler from the body of the vehicle to access these bolts. This can be a delicate process, so take your time and be careful not to damage any other components.

Once you have accessed the bolts, use the appropriate tool to carefully remove them. Place them somewhere safe so that you can find them easily when it's time to reassemble the parts. With the bolts removed, you should now be able to lift the cap away from the filler. It may be helpful to have a second person assist you with this step to avoid putting strain on any other parts of the vehicle.

If you are having difficulty removing the cap, there could be a clamp or other component that is holding it in place. Check under the bedside fender panel for any connections between the fuel tank filler hose and the fuel cap opening. You may need to disconnect any clamps or hoses before you can fully remove the cap.

It is important to note that working on fuel systems can be dangerous, and it is always recommended to seek professional assistance if you are unsure about any part of the process.

Frequently asked questions