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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.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. If removing the fuel tank for replacement of the fuel tank or the fuel tank solenoid valve, perform the Pressure Relief - Fuel Tank Venting procedure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION-NATURAL GAS .
    3. NOTE: The jackscrew on the extended range fuel tank is accessed through an access hole in the vapor retaining cover.
    Fig 1: Identifying Manual Lockdown Valve Jackscrew
    G02766121Courtesy of FORD MOTOR CO.
  3. If removing the fuel tank for replacement of lines, turn in the manual lockdown valve jackscrew on the fuel tank solenoid valve.
  4. Carry out the Pressure Relief - Fuel Line Venting procedure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION-NATURAL GAS .
  5. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  6. Disconnect the electrical connectors.
    Fig 2: Disconnecting Electrical Connectors
    G02766122Courtesy of FORD MOTOR CO.
    7. NOTE: Loosen the fittings slowly to allow any excess tube pressure to vent through the fitting connection.
    Fig 3: Disconnecting Upper Fuel Tube And The Flexible Tube Retainer Bolts
    G02766123Courtesy of FORD MOTOR CO.
  7. Disconnect the upper fuel tube and the flexible tube retainer.
    1. Loosen the fitting and disconnect the upper fuel tube.
    2. Remove the nuts and position the fuel tubes and wiring harness into the luggage compartment.
  8. Remove the rear seat. For additional information, refer to SEATING .
  9. Remove the bolts and nuts.
    Fig 4: Remove The Bolts And Nuts
    G02766124Courtesy of FORD MOTOR CO.
  10. Remove the bolts and the partition separator.
    Fig 5: Removing Partition Separator
    G02766125Courtesy of FORD MOTOR CO.
  11. Remove the bolts.
    Fig 6: Removing Bolts
    G02766126Courtesy of FORD MOTOR CO.
  12. Remove the bolts and the frame and shield assembly.
    Fig 7: Removing Frame And Shield Assembly
    G02766127Courtesy of FORD MOTOR CO.
  13. Remove the bolts.
    Fig 8: Removing Bolts
    G02766128Courtesy of FORD MOTOR CO.
  14. Remove the bolts and the fuel tank straps.
    Fig 9: Removing Fuel Tank Straps Bolts
    G02766129Courtesy of FORD MOTOR CO.
  15. Install the lifting equipment and remove the extended range fuel tank.
    Fig 10: Removing Extended Range Fuel Tank
    G02766130Courtesy of FORD MOTOR CO.
    16. NOTE: Replace the fuel tube O-ring seal.
    NOTE: Lubricate O-rings seal with clean engine oil 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 .
  16. To install, follow the removal procedure in reverse order.
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