Removal and Installation

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

ALL VEHICLES

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
If removing the fuel tank assembly for replacement of the fuel tank(s) or the fuel tank solenoid valve(s), perform the Pressure Relief - Fuel Tank Venting procedure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION-NATURAL GAS .
If removing the fuel tank assembly for replacement of the support straps or the spacers, turn in the manual lockdown valve jackscrews on the fuel tank solenoid valves.

Fig 1: Identifying Manual Lockdown Valve Jackscrew
Courtesy of FORD MOTOR CO.
Carry out the Pressure Relief - Fuel Tube Venting procedure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION-NATURAL GAS .
Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .

ALL VEHICLES EXCEPT E-450

Remove the front stone shield retaining bolts.

Fig 2: Removing Front Stone Shield Retaining Bolts (All Vehicles Except E-450)
Courtesy of FORD MOTOR CO.
Remove the rear stone shield retaining bolts and the stone shield.

Fig 3: Removing Rear Stone Shield Retaining Bolts (All Vehicles Except E-450)
Courtesy of FORD MOTOR CO.
Remove the tank support strap retaining bolts and the tank support strap.

Fig 4: removing Tank Support Strap Retaining Bolts (All Vehicles Except E-450)
Courtesy of FORD MOTOR CO.

E-450 VEHICLES

Remove the front stone shield retaining bolts.

Fig 5: Removing Front Stone Shield Retaining Bolts (E-450 Vehicles)
Courtesy of FORD MOTOR CO.
Remove the rear stone shield retaining bolts and the stone shield.

Fig 6: Removing Rear Stone Shield Retaining Bolts (E-450 Vehicles)
Courtesy of FORD MOTOR CO.
Remove the tank support strap retaining bolts and the tank support strap.

Fig 7: Removing Tank Support Strap Retaining Bolts (E-450 Vehicles)
Courtesy of FORD MOTOR CO.

ALL VEHICLES

Disconnect the fuel tank assembly solenoid valves.
- Disconnect the electrical connectors from the fuel tank solenoid valves.
- Disconnect the high-pressure fuel tube from the forward fuel tank solenoid valve.
Fig 8: Removing Fuel Tank Assembly Solenoid Valves
Courtesy of FORD MOTOR CO.
Install the Powertrain Lift with Tilting Plate and NGV fuel cell handler rubber pad.
1. Position the Power Lift with Tilting Plate and NGV fuel cell handler rubber pad.
2. Secure the fuel tank assembly with a nylon tie-down strap.
Fig 9: Installing Powertrain Lift With Tilting Plate And NGV Fuel Cell Handler Rubber Pad
Courtesy of FORD MOTOR CO.
Remove the front fuel tank assembly retaining nuts.

Fig 10: Removing Fuel Tank Assembly Retaining Nuts
Courtesy of FORD MOTOR CO.
Remove the rear fuel tank assembly retaining bolts.

Fig 11: Removing Rear Fuel Tank Assembly Retaining Bolts
Courtesy of FORD MOTOR CO.
Carefully lower and remove the aft-axle fuel tank assembly from the vehicle.

Fig 12: Removing Aft-Axle Fuel Tank Assembly From Vehicle
Courtesy of FORD MOTOR CO.

NOTE: Replace the fuel tube O-ring seal.

NOTE: Lubricate the fuel tube O-ring seal with clean engine oil meeting prior to installation.

NOTE: When tightening the fuel tube, a torque wrench adapter must be used with the torque wrench. The use of a torque wrench adapter will alter the effective torque of the torque wrench being used. To correct the effective torque, a torque multiplication conversion must be used. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION-NATURAL GAS .

NOTE: After installation, perform the fuel system leak test procedure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION-NATURAL GAS .

To install, reverse the removal procedure.