Replacing The Fuel Tank In Your 1996 Ford F150 Pickup

If you're looking to replace the fuel tank in your 1996 Ford F-150 pickup, there are a few things you should know. This job requires some mechanical skills and the right tools, but it can be done in a few hours. You'll need to drain the fuel tank, remove the negative battery cable, and disconnect the fuel lines and hoses. It's important to take safety precautions, such as wearing safety glasses and disconnecting the battery cables to eliminate any chance of a spark. You'll also need tools like a fuel line quick disconnect tool, pliers, a regular screwdriver, and sockets. The total cost for this project should be the price of the tank, which is around $122, plus any additional tools you may need to purchase.

Removing the filler hose

Before starting, ensure that you have the necessary tools, such as pliers, a regular screwdriver, and a fuel line quick disconnect tool. It is also important to prioritise safety by wearing protective gear like safety glasses and avoiding any open flames or sparks near the tank.

Now, let's begin the process of removing the filler hose:

• Loosen the hose clamps: Use a screwdriver to loosen the hose clamps that secure the filler tube and vent tube. This will make it easier to detach the hoses later.
• Prepare for tank lowering: Attach slide latching straps or a floor jack with a wide wooden support to the fuel tank. This will help control the lowering of the tank later.
• Disconnect one end of the filler and vent hose: Once the straps are tight and secure, you can start to remove the bolt from the metal strap that holds the tank in place. Then, disconnect one end of the filler and vent hose where you released the clamps earlier.
• Lower the tank: By gradually releasing the tension on the straps, you can start to lower the tank. Lower it until you have access to the fuel line and hose connections.
• Disconnect the fuel lines and sensor hoses: There will be two fuel lines and three smaller sensor hoses with spring compression clamps. Carefully detach these hoses, ensuring that the fuel lines remain upright to prevent any gas spillage.
• Handle the sensors with care: The fuel tank has three sensors: two grey and one black. The black sensor is particularly expensive, so be cautious when removing it. Spray around the sensors with WD-40 or a similar product, and then push down and turn them a quarter turn counter-clockwise to remove them.

By following these steps, you will have successfully removed the filler hose and disconnected the fuel tank from the associated hoses and sensors. Remember to take your time and work carefully to avoid any damage or spills.

Disconnecting the battery cables

Locate the Battery:

First, you need to find the battery. In most vehicles, including the Ford F-150, the battery is located under the hood, bolted in place near the engine bay's surface. If you're having trouble locating it, refer to your owner's manual, which will provide specific instructions for your vehicle.

Identify the Positive and Negative Terminals:

This step is crucial for ensuring you disconnect the cables correctly. The positive terminal is marked with a "+" sign, while the negative terminal is marked with a "-". They may also be distinguished by colour, with the positive terminal typically being red and the negative terminal black. Plastic caps may cover these terminals, which you will need to remove.

Gather the Right Tools:

To disconnect the battery cables, you'll need the appropriate wrenches. Most battery cable clamps have 10-millimetre bolts, so a 10-millimetre open-end wrench or a socket wrench of the same size will likely be needed. It's a good idea to have a set of wrenches or a socket wrench set with various sizes to ensure a proper fit.

Unbolt and Disconnect the Negative Cable:

Make sure the ignition is off before beginning this step. Wear eye protection for added safety. Using the appropriate wrench, carefully loosen the nut on the negative terminal, then disconnect the negative cable by lifting it away from the battery. Be cautious not to let the wrench touch both the negative and positive terminals simultaneously. Even a dead battery may have residual electricity, which could create a spark or short circuit.

Unbolt and Disconnect the Positive Cable:

Once the negative cable is safely disconnected and moved out of the way, repeat the same process for the positive cable. Ensure that you push the positive cable away from the battery and that it does not come into contact with the negative terminal.

Additional Tips:

Some modern vehicles may have "seized" cables, which are firmly attached to the battery post or tray. In such cases, a battery cable removal tool may be required. Consult your local auto parts store or manufacturer to see if you need one for your specific vehicle.

Additionally, always be mindful of safety. Wear protective gloves and safety goggles if possible. Remember to follow the correct order of disconnecting the cables, as the negative cable is typically disconnected first to prevent accidental short circuits.

By carefully following these steps, you will have successfully disconnected the battery cables in your 1996 Ford F-150 pickup, allowing you to proceed with replacing the fuel tank or performing other maintenance tasks.

Draining the tank

To drain the tank of your 1996 Ford F-150, you have a few options. Firstly, you could try removing the filler hose, which is the large hose with a smaller hose inside it. Once the small hose is taken out, you can try to insert a siphon hose into the larger hose to drain the tank. However, this may be challenging due to a possible screen at the tank entrance that blocks the insertion of any hose.

Another method is to remove the bed of the truck, providing easier access to the tank. This can be a complicated process, and you may need assistance from several people to lift the bed off. If you choose to do this, make sure to remove all bed bolts except the back two, and only raise the front of the bed enough to access the pump.

If you want to avoid removing the bed, you can try using a floor jack with a wide piece of wood for support to lower the tank. This will give you access to the tank without fully removing the bed.

Before beginning any of these methods, ensure you take the necessary safety precautions. These include wearing safety glasses to protect your eyes from dirt and rust, avoiding smoking or open flames near the tank, and disconnecting the battery cables to prevent sparks and fuel pump operation.

Using a floor jack to lower the tank

To replace the fuel tank in your 1996 Ford F-150 pickup, you'll need to lower the tank using a floor jack. Here's a step-by-step guide on how to do it:

Before you begin, ensure your Ford F-150 is parked on a flat and safe surface with the engine turned off. It is important to work on a level surface to prevent the vehicle from rolling or shifting during the process. Additionally, make sure you wear safety gear, such as gloves and eye protection, to safeguard against any potential hazards.

Start by removing the negative battery cable to disconnect the battery. This is a safety precaution to eliminate any chance of a spark and to prevent the fuel pump from running while you work.

Next, locate the fuse for the fuel pump in the fuse box under the hood in the engine compartment. Remove this fuse as well. Refer to your owner's manual if you're unsure about the fuse locations.

Now, you'll need to remove the filler tube and vent tube hose clamps. Loosen the two hoses slightly so that they can be removed more easily later on.

At this point, you can prepare the floor jack. Place a piece of wood or some soft padding on top of the jack to prevent damaging the fuel tank. Position the jack under the fuel tank, raising it just enough so that the jack supports the tank. You may need to adjust the height of the jack as you work to ensure the tank remains stable.

With the jack in position, you can start removing the bolts from the metal straps that hold the fuel tank in place. Be sure to have someone assist you in supporting the tank as you remove the bolts. Once the bolts are removed, carefully lower the tank using the jack.

As you lower the tank, you'll need to disconnect the filler and vent hoses, as well as the fuel lines and sensor hoses. Take your time with this step to avoid any spills or damage to the hoses and connections. There will be two fuel lines and three smaller sensor hoses, along with the electrical connector for the fuel pump, that need to be disconnected.

Once everything is disconnected, slowly lower the tank further until it reaches the ground. With the tank lowered, you can now replace or repair it as needed. Remember to exercise caution and patience throughout the process, and always have an assistant to help support the tank and ensure your safety.

When you're finished with the repairs or replacement, simply follow these steps in reverse to reinstall the fuel tank and reconnect all the hoses and connections.

Disconnecting the fuel lines and hoses

Before beginning, ensure you have the necessary tools, such as a fuel line disconnect tool and a screwdriver. These tools will aid in safely releasing the fuel line connections without causing any damage.

First, relieve the pressure in the fuel lines. This can be done by depressing the Schrader valve or disconnecting the inertia switch and disabling the fuel pump. By turning the key to start, you can let the engine run until it shuts down, releasing any built-up pressure.

Now, locate the fuel lines and hoses connected to the fuel tank. You will need to carefully pry or press the black plastic clips on the fittings to release them. Using a screwdriver, gently pry these clips off, being cautious not to damage the surrounding components.

In some cases, you may encounter metal latches on the fittings. For these, you can try flipping them up and pulling the fitting off the metal line. Alternatively, you may need to use a fuel line disconnect tool specifically designed for this purpose. These tools are inserted into the fitting and popped off, requiring a bit of force and a steady hand.

It's important to note that disposable plastic clips are often used in these connections, and they may break during the removal process. Have some replacements ready to ensure a secure connection when reassembling.

When disconnecting the lines, be prepared for some fuel spillage. Have rags or containers ready to catch any dripping fuel and prevent it from coming into contact with hot engine components.

Once the lines are disconnected, you can carefully lower the fuel tank and proceed with the necessary repairs or replacements. Remember to recap the ends of the fuel lines to prevent further leakage during the process.

By following these steps and taking your time, you can successfully disconnect the fuel lines and hoses on your 1996 Ford F150 pickup truck. Always prioritize safety and be cautious when working with flammable liquids like fuel.

Frequently asked questions