Make sure before you bring the tank all the way up.ī) Did you plut the elctrical connector back in? You can syphon out the tank before you raise it again if you need to. Expecially if you had a fair amount of fuel in the tank still. It may be a two person job to get it back together. Hopefully the electrical tape will hold and my car won't blow up.Ģ4) From here, reassemble everything in reverse order. Use more heat shrink tube if you have it. Ford sells the pump as a whole assembly, though we were able to buy the level sensor from Ģ0) Use a very small socket (don't know what size) to remove the small bolt on the bottom of the sensor assembly.Ģ1) Tilt the assembly away from the fuel pump and unclip it from the top of the aseembly.Ģ2) Disconnect the yellow butt connector and heat shrink tube.Ģ3) Plug in the new sensor. You will need to lead with the foam like filter on one end of the pump so that the floater will clear the opening.ġ9) Here is a good time to replace the whole fuel pump if that's what you want to do. One small twist counter clockwise and it will come right off.ġ8) Carefully remove the fuel pump assembly. Ford wants you to use a special tool to remove it. Driver side of the tank should drop free of the exhaust pipe.ġ6) Pull fuel tank out from under car (it's kinda big, isn't it?)ġ7) The fuel pump assmebly has a lock ring around it. Then pull the tank toward the passanger side of the car and then the rear of the car. (another clip connector)ġ2) disconnect electrical connection to fuel pump assembly (standard ford electrical clip connector)ġ3) Check to make sure nothing else is connected to the tank.ġ5) To remove the tank, make sure the passanger side of the tank drops freely. Place these in a safe place.ġ1) Remove the fuel line from the pump assembly on top of tank. One of these have clip-type connectors you need to remove. Don't over do it so that it's all dripping in your face though.Ĩ) Remove the fuel filler line from rear of tank (larger tube with tube clamp)ġ0) Disconnect vent lines. You might want to hit them with some WD40 or similar to help get them out. These bolts are about four inches long and come out slow because of rust. If the fuel system pressure has been release, you shouldn't get sprayed with fuelĦ) Place a Jack under the fuel tank and rise to tank levelħ) Use a 13 mm socket to remove the two strap bolts behind the fuel tank. Crank starter a while to make sure.Ħ) Sheilding your eyes for possible spray, use a thin object such as a pen to press the fuel line pressure valve on top of engine bay. (behind lining on right side of trunk)ĥ) Run vehicle until it dies (to run remaining fuel out of system). If you want to make sure without getting stranded, carry a fuel container with a couple gallons in it.ģ) Use large jack to raise rear of vehicle (you will need a good 9 inches to a foot of ground clearence) - Place on stationary jack stands.Ĥ) open trunk and disconnect the inertia cutoff switch. Remember that you still have a few gallons left even after your fuel light turns on. Now I need to run down that half tank and see if I can get the gas light to turn on.īefore you begin, make sure the fuel tank is as empty as possible. It at least works as well as it did before we took everything appart because I went to the gas station and put 5 gallons in and it went up to just below half a tank. It seems I didn't really have the tank empty below 1/4 of a tank or the guage still doesn't work right.
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