Removal and Installation

WARNING: This page is about a different car, the 2010 Ford Pickup, 2010 Ford F550 Super Duty, 2010 Ford F450 Super Duty, and 2010 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instructions may result in serious personal injury.

NOTE: This procedure is for diesel applications only.

NOTE: The fuel tank must be drained completely. Upon removal of the fuel level sensor, the tank must be inspected for contamination.

Remove the fuel tank. For additional information, refer to FUEL TANK - MIDSHIP .

NOTE: Clean the fuel tank of any dirt or foreign material before servicing the fuel level sensor. In extreme dirt or dusty conditions it may be necessary to wash the fuel tank using a water hose. Before removing the fuel level sensor, make sure that there is no residual dirt or foreign material around the fuel level sensor flange. If dirt or foreign material enter the fuel tank, damage to the fuel level sensor or other fuel system components may occur.

Clean the area around the fuel level sensor lock ring.

NOTE: Mark the orientation of the fuel level sensor on the fuel tank to aid in installation.

Using the Fuel Tank Sender Unit Socket, remove the fuel level sensor lock ring.
- To install, tighten to 81 Nm (60 lb-ft).
  
  Fig 1: Removing Fuel Level Sensor Lock Ring Using Fuel Tank Sender Unit Socket
  Courtesy of FORD MOTOR CO.

NOTE: The fuel level sensor must be handled carefully to avoid damage to the float arm.

Completely remove the fuel level sensor from the fuel tank.

NOTE: Make sure to install a new fuel level sensor gasket or fuel leakage could occur causing vehicle damage.

Remove and discard the fuel level sensor gasket.
To install, reverse the removal procedure.
- Make sure the fuel level sensor is installed in the same orientation as the original.