Fuel Tank: Installation

1. Position the fuel tank above the rear differential and heat shield assembly.
2. Raise the fuel tank into position and heat shield assembly.
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- Clean the bolts and weld nuts lightly with a wire brush.
- Apply the thread locking sealant to the bolt threads.
  Material: Motorcraft® Threadlock and Sealer / TA-25-B
- NOTE: To insure that the bolts are threaded in straight, start the bolts by hand and turn several threads before tightening.
  
  Position the fuel tank straps and install the bolts.
  
  Torque: 46 lb.ft (62.5 Nm)
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Reposition the LH emergency brake cable bracket and install the nut.
Torque: 18 lb.ft (25 Nm)

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Reposition the RH emergency brake cable bracket and install the nut.
Torque: 20 lb.ft (27.5 Nm)

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Connect the hose to the fuel tank and tighten the clamp.

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NOTE: The help of a assistant will be needed. Do not over articulate the driveshaft or damage may occur.

Align the index marks on the driveshaft to the rear axle pinion flange.

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- Apply the thread locking sealant to the new bolt threads.
  Material: Motorcraft® Threadlock and Sealer / TA-25-B
- Install the new driveshaft to pinion flange bolts in a star pattern.
  Torque: 41 lb.ft (55 Nm)
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- Clean the bolts.
- Apply thread locking sealant to the bolt threads.
  Material: Motorcraft® Threadlock and Sealer / TA-25-B
- Install the bolts.
  Torque: 35 lb.ft (48 Nm)
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Install the muffler and tailpipe. Refer to: Muffler and Tailpipe
NOTE: Inspect the surfaces of the Fuel Pump and Sender Unit flange and fuel tank O-ring seal contact surfaces. Do not polish or adjust the O-ring seal contact area of the fuel tank flange or the fuel tank. Install a new Fuel Pump and Sender Unit or fuel tank if the O-ring seal contact area is bent, scratched or corroded.

Install a new O-ring seal.
NOTE: Carefully install the Fuel Tank Sender Unit lock ring wrench to avoid damage to the fuel level sensor when removing the lock ring.

Using the special tool install the fuel level sensor lock ring. Use Special Service Tool: 310-123 Locking Ring, Fuel Tank.

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Refer to: Quick Release Coupling

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NOTE: Inspect the surfaces of the Fuel Pump and Sender Unit flange and fuel tank O-ring seal contact surfaces. Do not polish or adjust the O-ring seal contact area of the fuel tank flange or the fuel tank. Install a new Fuel Pump and Sender Unit or fuel tank if the O-ring seal contact area is bent, scratched or corroded.

Install a new Fuel Level Sensor O-ring seal.
NOTE: Carefully install the Fuel Tank Sender Unit lock ring wrench to avoid damage to the fuel level sensor when removing the lock ring.

Using the special tool install the fuel level sensor lock ring. Use Special Service Tool: 310-123 Locking Ring, Fuel Tank.

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NOTE: Make sure that the mating faces are clean and free of foreign material.

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Install the access cover.

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Install the rear seat cushion. Refer to: Rear Seat Cushion
Connect the battery ground cable. Refer to: Battery Disconnect and Connect