Section 10-01A: Fuel Tank, Filters, Tubes and Electric Fuel Pump, Gasoline Engines | 1996 F-150, F-250, F-350, F-Super Duty and Bronco with Gasoline Engines Workshop Manual |
NOTE: As there are different midship fuel tanks (9002) which are removed and installed essentially the same way, follow steps and refer to appropriate illustration for details.
Removal
NOTE: When the battery (10655) is disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM) (12A650) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.
Disconnect battery ground cable (14301).
Using Rotunda Fuel Storage Tanker 164-R3201 or equivalent, drain fuel tank. Drain both fuel tanks on dual-tank vehicles.
Raise vehicle on hoist.
If equipped with skid plate, remove fasteners and remove skid plate assembly.
Loosen clamps and disconnect fuel tank filler pipe (9034) and vent hose at fuel tank.
Position suitable jack under fuel tank.
Remove nuts and bolts and lower fuel tank support straps (9092). If necessary, turn fuel tank support strap approximately 30 degrees and remove.
Lower fuel tank enough to gain access to fuel connections.
Disconnect electrical connector from fuel tank sending unit and pump.
Disconnect fuel vapor hose(s) from port valve(s). If equipped, remove vent hose from clip on frame (5005).
Disconnect fuel supply and return tubes according to Push-Connect Fittings, Steel in the Removal and Installation portion of this section.
Remove fuel tank from vehicle.
Installation
Follow removal procedures in reverse order.
Tighten fasteners to specifications.
Midship Fuel Tank Installation, F-150, F-250, F-350 and F-Super Duty Chassis Cab, 116- and 138-Inch Wheelbase
| Item | Part Number | Description |
|---|---|---|
| 1 | 9K014 | Shield Assembly |
| 2 | 9092 | Fuel Tank Support Straps, Front |
| 3 | 9057 | Fuel Tank Support Strap, Rear |
| 4 | 9002 | Fuel Tank |
| 5 | N802253-S2 | Bolt |
| 6 | N620481-S | Nut |
| 7 | N620481-S2 | Nut |
| 8 | 9061 | Crossmember |
| 9 | N605919-S2 | Bolt |
| 10 | 5005 | Frame |
| 11 | 9C038 | Bracket |
| 12 | N605906-S2 | Bolt |
| 13 | N620482-S56 | Nut |
| 14 | N605906-S2 | Bolt |
| 15 | 9A147 | Skid Plate Heat Shield |
| 16 | N605906-S20 | Bolt |
| 17 | 9240 | Insulator, Upper |
| 18 | N804340-S2 | U-Nut |
| A | — | Tighten to 30-40 Nm (22-30 Lb-Ft) |
| B | — | Tighten to 16-24 Nm (12-17 Lb-Ft) |
| C | — | Tighten to 34-46 Nm (25-34 Lb-Ft) |
Midship Fuel Tank Installation, F-150, F-250, F-350 and F-Super Duty Chassis Cab
| Item | Part Number | Description |
|---|---|---|
| 1 | N620481-S2 | Nut |
| 2 | N804340-S2 | U-Nut |
| 3 | N605906-S2 | Bolt |
| 4 | N605906-S2 | Bolt |
| 5 | 9A148 | Skid Plate |
| 6 | 5005 | Frame |
| 7 | 9092 | Fuel Tank Support Strap, Front |
| 8 | 9002 | Fuel Tank |
| 9 | 9092 | Fuel Tank Support Strap, Rear |
| 10 | 9K014 | Shield |
| 11 | N802253-S2 | Bolt |
| 12 | N620482-S2 | Nut |
| 13 | N801107-S100 | U-Nut |
| 14 | 9240 | Insulator, Upper |
| 15 | 9065 | Bracket |
| 16 | N605906-S2 | Bolt |
| 17 | N620481-S2 | Nut |
| A | — | Tighten to 16-24 Nm (12-17 Lb-Ft) |
| B | — | Tighten to 30-40 Nm (22- 30 Lb-Ft) |
| C | — | Tighten to 22-28 Nm (17-21 Lb-Ft) |