Section 10-01B: Fuel Tank, Filters, Tubes and Fuel Pump, Diesel Engine | 1996 F-Series and F-Super Duty Vehicles Equipped with Diesel Engines Workshop Manual |
Procedures are the same for aft-of-axle and midship fuel tank filler pipes (9034).
Removal
Disconnect battery ground cable (14301) and drain fuel to a level (approximately 3/4 full) below fuel tank filler connection by using Rotunda Fuel Storage Tanker 164-R3201 or equivalent.
Loosen clamp attaching filler pipe hose to fuel tank filler neck. Disconnect filler pipe hose, pulling along rubber inner tube from filler neck.
Disconnect fill vent hose at vapor valve.
Remove three retainer screws that attach filler pipe neck to body/box fuel filler housing.
Remove fuel tank filler pipe from vehicle.
Remove hose and clamps. Replace cracked or leaking hoses or other damaged parts.
Installation
Position fuel tank filler pipe in vehicle.
Position clamp on filler pipe hose-to-filler pipe neck connection and insert rubber inner tube in filler neck. Make sure that the inner tube is not kinked or twisted in the neck and in the outer filler hose.
Install three retainer screws attaching filler pipe neck to body/box fuel filler housing. Tighten to 2.7-3.7 Nm (23-32 lb-in).
| Item | Part Number | Description |
|---|---|---|
| 1 | 9002 | Fuel Tank |
| 2 | 9030 | Fuel Tank Filler Cap |
| 3 | N802826-555M | Screw |
| 4 | 9034 | Fuel Tank Filler Pipe |
| 5 | 383526-3 | Clamp |
| 6 | 5005 | Frame |
| 7 | W700574-S300 | Clamp |
| 8 | 9B593 | Evaporative Emission Valve |
Reconnect fill vent hose at vapor valve.
Adjust hose to obtain snug filler pipe installation. Tighten hose clamps to 2.7-3.7 Nm (23-32 lb-in). Make certain clamps are forward of flange on filler pipe to ensure a leakproof connection.
Fill fuel tank (9002) with fuel. Install fuel tank filler cap (9030) and check for leaks.
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.
Reconnect battery ground cable.
| Item | Part Number | Description |
|---|---|---|
| 1 | 9002 | Fuel Tank |
| 2 | 9030 | Fuel Tank Filler Cap |
| 3 | N802826-S55M | Screw |
| 4 | 9034 | Fuel Tank Filler Pipe |
| 5 | 383526-S | Clamp |
| 6 | 5005 | Frame |
| 7 | — | Outer Hose (Part of 9002) |
| 8 | — | Inner Hose (Part of 9002) |
| A | — | Tighten to 2.7-3.7 Nm (23-32 Lb-In) |
| B | — | Install Clamp in This Area (Beyond First Bead and Before Hose End) |
| C | — | For Pipes Without Secondary Bead |
| D | — | 23.0mm Engagement |
| E | — | Install Hose Within 1.5mm of Secondary Positioning Bead Where Applicable |
| F | — | Paint Stripes |
| Item | Part Number | Description |
|---|---|---|
| 1 | 9002 | Fuel Tank |
| 2 | 5005 | Frame |
| 3 | N802826-S55M | Screw |
| 4 | 9030 | Fuel Tank Filler Cap |
| 5 | 9034 | Fuel Tank Filler Pipe |
| 6 | 383526-S | Clamp |
| 7 | — | Outer Hose (Part of 9002) |
| 8 | — | Inner Hose (Part of 9002) |
| A | — | Tighten to 2.7-3.7 Nm (23-32 Lb-In) |
| B | — | Install Hose Within 1.5mm (.06 Inch) of Secondary Positioning Bead Where Applicable/td> |
| C | — | 23.0mm (.90 Inch) Engagement |
| D | — | For Pipes Without Secondary Bead |
| E | — | Install Clamp in This Area (Beyond First Bead and Before Hose End) |
| F | — | Paint Stripes |
| G | — | Install Hose with Stripes in Line with Two Dimples on Fuel Tank |
| Item | Part Number | Description |
|---|---|---|
| 1 | 9170 | Hose, Fuel Tank Vent Tube |
| 2 | 383522-S | Clamp |
| 3 | 9B213 | Support, Fuel Tank Filler Pipe |
| 4 | 9030 | Fuel Tank Filler Cap |
| 5 | N802826-S55M | Screw and Washer (3 Req'd) |
| 6 | 9034 | Fuel Tank Filler Pipe |
| 7 | 383526-S | Clamp |
| 8 | 9047 | Hose, Fuel Tank Filler |
| A | — | Tighten to 17-28 Nm (13-21 Lb-Ft) |