Replacing The Fuel Pump In A 2006 Ford F150: Step-By-Step Guide

If you're having trouble firing up the engine of your 2006 Ford F-150 or experiencing strange idling, it could be that your fuel pump is on its last legs. The fuel pump is a component that can wither over time, and you may need to replace it. This is a complex process that requires either removing the fuel tank or the bed of the truck to access the pump. Before attempting this, ensure your vehicle is on a flat and safe surface, and the engine is off. You will also need to drain the gas tank.

Siphon gas and use a car jack and stands to remove the fuel tank

To replace the fuel pump on a 2006 Ford F-150, you'll need to siphon the gas from the tank and use a car jack and stands to remove the fuel tank. Here's a detailed guide on how to do it:

Siphon the Gas:

• Park your vehicle on a flat, hard, and level surface.
• Place a clean, uncontaminated gas can near the tank.
• Get a siphon pump. You can use a manual or automatic one.
• Place one end of the hose in the fuel tank, and insert the other end into the gas can.
• If using a manual pump, pump it several times to start the flow of fuel. With an automatic pump, press the button to start the flow.
• Once the gas can is full, elevate the hose inside to stop the flow and let excess fuel seep back into the tank.
• Carefully remove the pump and seal your gas tank to prevent contamination.

Use a Car Jack and Stands to Remove the Fuel Tank:

• Park your car on level ground, preferably on a paved surface.
• Block the wheels: if you're lifting the rear, chock the front wheels, and vice versa.
• Put the car in park and engage the emergency brake. If it's a manual transmission, put it in first gear and also engage the parking brake.
• Place wheel wedges, wood blocks, or bricks behind the wheels to prevent accidental rolling.
• Position the car jack under the car frame. Consult your owner's manual for the correct placement.
• Raise the car to the desired height.
• Place the jack stands under the car frame at reinforced points or "pinch welds" near the jack.
• Lower the vehicle onto the jack stands.
• Locate the fuel tank under the vehicle.
• Remove the fuel tank hoses using a ratchet and socket. Loosen the hose clamp on the fuel filler tube and vent tube, then remove the hoses.
• Place a transmission jack under the fuel tank and lift it until it makes contact.
• Remove the straps holding the fuel tank using a ratchet and socket. Loosen and remove the fuel tank straps by unscrewing the strap mounting bolt.
• Lower the fuel tank gradually.
• Disconnect all electrical connections and fuel lines from the top of the tank.
• Carefully lower the fuel tank further as needed to access the filler tubes and vent pipes.
• Continue lowering the fuel tank to the ground or to a position where you can perform the necessary repairs.

Remove the heat shield and fuel tank bolts

To remove the heat shield and fuel tank bolts, first make sure your Ford F-150 is on a flat and safe surface and that the engine is off. You will need an impact wrench to remove the bolts.

Once your truck is safely and securely raised, crawl under the truck and locate the heat shield. You will notice two sets of bolts. One set holds the heat shield in place, and the other set holds the fuel tank in place. First, locate the bolts that hold the heat shield. They will be aligned with the heat shield strap.

After removing the bolts, the heat shield will start to drop as you remove it. Place your knee against it so it doesn't fall on you as you wiggle it free. Once it is free, put it aside.

Now, grab two floor jacks and place them underneath the fuel tank to support it as you remove its bolts. Be sure that the jacks are raised just enough to support the tank. It's also a good idea to insert some soft padding between the jack stand and the tank to prevent damage.

Use your impact wrench to remove the four long bolts from the fuel tank. Once both straps are loosened, lower the straps and twist them off gently. Don't force them or you will wind up ruining the mounting point. Set the two straps and the bolts to the side.

Now your fuel tank should be supported only by the jack stands. Ask someone to slowly lower the stands while you hold the fuel tank. The front end won't drop right away because it is connected to the fuel fill line. You will need a 1/4 inch hex socket to remove this connection.

Once the fuel fill line is disconnected, your assistant can lower the jack stands, and you should be able to pull the fuel tank out from under the truck.

Disconnect the fuel filler cap and neck clamp

Disconnecting the fuel filler cap and neck clamp is a crucial step when replacing the fuel pump on a 2006 Ford F-150. Here is a detailed, step-by-step guide on how to do it:

Step 1: Disconnect the Fuel Filler Cap

Locate the three 7mm bolts that hold the filler cap in place and remove them using the appropriate screwdriver or wrench. Once the bolts are loosened, let the cap hang down.

Step 2: Remove the Filler Neck Clamp

Climb down under the truck, just beneath the gas cap. You will find a clamp that connects the filler neck to the bed of the truck. Loosen this clamp to disconnect the filler neck from the bed. Be careful not to force it, as you may damage the mounting point.

Step 3: Understanding the Process

Disconnecting the fuel filler cap and neck clamp is part of the process of removing the truck bed to access the fuel pump. This is an alternative to removing the fuel tank, which can be a more challenging option due to the need to work underneath the vehicle and deal with rusty connections.

By removing the truck bed, you gain easier access to the fuel pump, which is located just behind the cab. This process involves disconnecting the bed and tail lights, removing the bolts holding the bed in place, and carefully lifting the bed off the truck with the help of a couple of strong assistants or equipment like bed hooks, ropes, and a chain hoist.

Once the truck bed is removed, you can proceed to locate and clean the fuel pump module, which is the same process for both options.

Safety Precautions:

Always ensure your Ford F-150 is on a flat and safe surface, and the engine is off before performing any repairs or maintenance. Additionally, it is crucial to drain the gas tank before starting any work related to the fuel pump.

Disconnect the bed and tail lights

Disconnecting the bed and tail lights is a crucial step when replacing the fuel pump on a 2006 Ford F-150. Here is a detailed, step-by-step guide on how to do it:

Step 1: Remove the Bed

Climb onto the bed of your truck and use an impact wrench to remove the six bed bolts. These bolts secure the bed to the truck, so removing them will allow you to lift the bed off. Be sure to have a clear workspace and wear the necessary safety gear, such as gloves and eye protection.

Step 2: Disconnect the Fuel Filler Cap

The fuel filler cap is located near the gas cap and is held in place by three 7mm bolts. Loosen these bolts and let the cap hang down. This step is important as it disconnects the fuel filler from the bed, allowing you to remove the bed completely.

Step 3: Remove the Filler Neck Clamp

Climb down under the truck, just beneath the gas cap. You will find a clamp that connects the filler neck to the bed of your truck. Loosen this clamp to separate the filler neck from the bed. This step ensures that the filler neck does not get damaged when you remove the bed.

Step 4: Disconnect the Bed and Tail Lights

Slide further underneath your truck bed and locate the wire harness for the bed lighting. This harness is usually found in the left rear corner of the bed. Pull on the two connectors until they come loose. Be careful as dirt may fall into your eyes! Move the wire harness out of the way.

Next, remove the two taillight plugs located at each corner of the back of the bed. These plugs provide power to the taillights, so removing them will completely disconnect the bed and tail lights.

At this point, you have successfully disconnected the bed and tail lights. The next step would be to lift the bed off the truck, which requires the help of two strong individuals or the use of bed hooks, ropes, and a chain hoist.

Important Note:

Always refer to a qualified mechanic or a detailed guide when performing any vehicle repairs or maintenance. The above instructions are meant to provide a general overview of the process, and additional steps or precautions may be necessary for your specific vehicle.

Remove the fuel pump module and clean the fuel tank

To remove the fuel pump module and clean the fuel tank of your 2006 Ford F-150, follow these steps:

First, make sure you have less than a quarter tank of gas. Then, remove the three screws from around the filler neck and loosen the hose clamp from inside the rear driver's wheel well. Position a jack against the tank and remove the straps and bolts. Lower the tank slightly and remove the wire holders from the frame to give yourself more slack when lowering the tank.

Now, you can start disconnecting the fuel lines and hoses from the fuel pump. Push in the tab on the fuel line connector with a flat-head screwdriver and pull the line off. Do the same for the vent canister tube, filler vent tube, and small canister tube. Be careful not to break the clips, especially the yellow one, as it is nearly impossible to find a replacement. If you do break a clip, use tape to attach the hose to avoid leaks, and replace it later.

Next, drop the tank to the ground and cover the open filler hole on top. Make sure to cap any open nipples on the fuel pump to prevent leaks. Before removing the fuel pump, make sure you have the correct replacement by checking your wheelbase size. You can find this information in your owner's manual or by contacting a Ford dealer with your Vehicle Identification Number (VIN).

Now, you can remove the fuel pump. Clean the area around the top of the fuel pump and, using a wooden mallet, tap and spin off the retainer from the top of the pump. Lift the pump slightly and remove the quick-connect fitting under the fuel pump in the tank by pushing in the tab and pulling the connector off. Some tanks may not have this quick-connect fitting. Once the retainer is removed, the pump may pop up by itself.

At this point, you can start cleaning the fuel tank. Use a scoop or your hand to remove as much of the crud or rust from the bottom of the tank as possible. If the tank is heavily rusted or contaminated, consider purchasing a replacement tank instead of trying to clean it thoroughly.

Finally, install the new fuel pump assembly. Remember to add some oil around the gasket and all quick-connect fittings to ensure a proper seal. Reattach the fuel lines and hoses, making sure to line up the clips correctly. Carefully lower the tank back into place and reattach the straps and bolts.

Always exercise caution when working with flammable liquids and gases. Ensure proper ventilation and avoid any activities that may create sparks, such as welding or grinding, when working around the fuel tank and fuel pump.

Frequently asked questions