Fuel Tank - Aft-of-Axle: Removal

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E550 Super Duty, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury.

WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.

NOTE: The 55 gallon aft-of-axle fuel tank (9002) is shown; the 35 gallon aft-of-axle fuel tank is similar.

Disconnect the battery ground cable.
Relieve the fuel pressure; refer to FUEL SYSTEM-GENERAL INFORMATION-GASOLINE & DIESEL .
Drain the fuel from the fuel tank; refer to FUEL SYSTEM-GENERAL INFORMATION-GASOLINE & DIESEL .
Raise and support the vehicle.

NOTE: In this illustration, the vehicle body is shown removed for clarity.

Fig 1: Disconnecting Fuel Tank Filler Pipe

Courtesy of FORD MOTOR CO.

Disconnect the fuel tank filler pipe (9034) and the filler vent tube from the fuel tank.
Position the jack under the fuel tank.
Remove the bolts.

Fig 2: Removing Bolts
Courtesy of FORD MOTOR CO.
Remove the nuts.

Fig 3: Removing Nuts
Courtesy of FORD MOTOR CO.
Remove the fuel tank support straps (9092).
Partially lower the fuel tank.
Disconnect the fuel lines from the fuel pump (9350); refer to FUEL SYSTEM-GENERAL INFORMATION-GASOLINE & DIESEL .

Fig 4: Disconnecting Fuel Lines From Fuel Pump
Courtesy of FORD MOTOR CO.
Disconnect the fuel pump and fuel tank sending unit electrical connector.

Fig 5: Disconnecting Fuel Pump
Courtesy of FORD MOTOR CO.
On gasoline fuel tanks, disconnect the hose(s) from the evaporative emission valve (9B593).

Fig 6: Disconnecting Hose(s) From Evaporative Emission Valve
Courtesy of FORD MOTOR CO.
On gasoline fuel tanks only, disconnect the fuel tank pressure sensor electrical connector.

Fig 7: Disconnecting Fuel Tank Pressure Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Lower the fuel tank.
If the fuel tank is being replaced, transfer the fuel pump, fuel tank sending unit, the evaporative emission valves and the fuel tank pressure sensor (gasoline fuel tanks) or the plug (diesel fuel tanks) to the new fuel tank.