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
REMOVAL AND INSTALLATION

Fuel Tank, Aft-of-Axle, F-150, F-250, F-350 and F-Super Duty

Removal

 CAUTION: Care must be taken when installing the fuel tank (9002) to make sure the fuel tubes do not become kinked.

  1. Raise the rear of the vehicle.

  1. 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.

    To avoid electrical sparking at the fuel tank, disconnect battery ground cable (14301). Then disconnect the connector from fuel tank sending unit and pump near the fuel tank.

  1. Using Rotunda Fuel Storage Tanker 164-R3201 or equivalent, drain fuel tank. Drain both fuel tanks on dual tank vehicles.

  1. Disconnect the fuel tube push-connect fittings at the fuel tank sending unit and pump, according to instructions in Push-Connect Fittings, Steel in the Removal and Installation portion of this section.

  1. Loosen the clamp on the fuel tank filler pipe (9034). Disconnect the fuel tank filler pipe by pulling along the rubber inner tube from the filler neck.

  1. If removing the metal-type fuel tank, support the fuel tank and remove the bolts attaching the fuel tank support strap (9092) to the frame (5005). Carefully lower the fuel tank and disconnect the vent tube(s) from the vapor emission control valve in the top of the fuel tank. Finish removing the fuel tank filler pipe and fuel tank filler pipe vent hose if not possible in Step 5. Remove the fuel tank from under the vehicle.

  1. If removing the plastic-type fuel tank, support the fuel tank and remove the bolts attaching the combination skid plate and tank support to the frame. Carefully lower the fuel tank and disconnect the vent tube(s) from the vapor emission control valve in the top of the fuel tank. Complete removing the fuel tank filler pipe if not possible in Step 5. Remove the skid plate and fuel tank from under the vehicle. Disassemble the skid plate from the tank.

 

Installation

  1. Follow removal procedures in reverse order.

  1.  CAUTION: The frame crossmember in front of the tank is narrower at the center to provide clearance for the fuel tubes. Be sure the tubes cross this portion of the crossmember on reinstallation to prevent damage to the tubes and restriction of fuel flow.

    Grasp the three hoses about 300mm (12 inches) forward of the crossmember. Hold the hoses taut while installing the fuel tank. This will prevent the fuel tubes from becoming kinked, which will cause restricted fuel flow.

  1. Use a thread adhesive (such as Loctite® or equivalent) on metal fuel tank attaching nuts and bolts. Tighten all fasteners to specifications.

    Steel Aft-of-Axle Tank Installation, F-150, F-250, F-350, 116-, 113-, 138- and 115-Inch Wheelbase

    ItemPart NumberDescription
    19002Fuel Tank
    29092Fuel Tank Support Strap
    3N801380-S100Bolt
    4382873-S2Washer
    5N620482-S2Nut
    69C045Stone Shield (LH)
    79053Fuel Tank Support
    89240Insulator
    99K015Stone Shield (RH)
    1034976-S362Nut
    ATighten to 34-46 Nm
    (25-34 Lb-Ft)

    Plastic Aft-of-Axle Tank Installation, F-350, 136.8- and 160.8-Inch Wheelbase

    ItemPart NumberDescription
    19C385Fuel Pump Locking Retainer Ring
    29092Fuel Tank Support Strap
    3W623484-S2Spring Washer
    49B227Hose and Valve Assembly
    59B076Seal
    69002Fuel Tank
    7N620482Nut, M10-1.5
    89A148Skid Plate
    9N605920-S2Bolt, M10-1.5
    10379930-S2Nut
    1156741Bolt, M10-1.5
    125037Crossmember
    13N605801-S2Bolt
    1440949-S2Screw
    159A032Shield
    165005Frame
    179B100Shield
    ATighten to 34-46 Nm
    (25-34 Lb-Ft)
    BTighten to Expose Thread Length 16-18mm
    (0.63-0.70 Inch)
    CTighten to 10-14 Nm
    (8-10 Lb-Ft)
    DTighten to 53-72 Nm
    (39-53 Lb-Ft)
 

Fuel Tank, Aft-Of-Axle, F-Super Duty Motorhome Chassis

Aft-of-Axle 75-Gallon Tank

ItemPart NumberDescription
15C054Crossmember
2N802114-S2Bolt
3N800898-S2Bolt
4N808660-S100Nut
5N804446-S160Nut
69002Fuel Tank
79092Fuel Tank Support Straps
89B007Fuel Tank Shield
(RH Exhaust Only)
9W611636-S2Screw
10N801616-SWasher
11N805320-S36Nut
129H307Fuel Tank Sending Unit and Pump
139276Fuel Level Sensor Gasket
149240Fuel Tank Insulator
ATighten to 60-96 Nm
(44-70 Lb-Ft)
BTighten to 60-90 Nm
(44-67 Lb-Ft)
CTighten to 20-30 Nm
(15-22 Lb-Ft)
DTighten to 7.5-9.5 Nm
(67-84 Lb-In)
EAllow 6mm (0.23 Inch) Gap