Before you begin:
* Safety First: Work in a well-ventilated area, away from any ignition sources (open flames, sparks, cigarettes). Have a fire extinguisher readily available. Wear safety glasses and gloves.
* Consult your repair manual: A factory service manual for your specific vehicle is invaluable. It will provide detailed diagrams and instructions.
* Obtain the necessary tools: You'll need various wrenches (metric), sockets, fuel line disconnect tools, jack stands, jack, safety straps, and possibly a fuel tank hoist or straps.
* Empty or significantly lower the fuel tank: This is crucial for safety. Drive the truck until near empty. Siphoning some fuel might be necessary, but be extremely careful during this process.
* Ground yourself: Touch a metal part of the truck frame before handling any fuel lines or components to avoid static electricity buildup.
Procedure:
1. Disconnect the Battery: Disconnect the negative (-) battery terminal first, then the positive (+) terminal. This prevents accidental shorts.
2. Locate and Disconnect Fuel Lines: These are usually located at the rear of the tank. You'll likely find two lines: a fuel supply line and a fuel return line. You might also have a vent line.
* Pressure Relief: Before disconnecting the fuel lines, relieve any pressure in the fuel system. This can often be done by starting the engine and letting it run until it stalls due to lack of fuel, or by using a fuel pressure release tool (consult your repair manual).
* Disconnecting the lines: Use the appropriate fuel line disconnect tools. These tools prevent damage to the lines and ensure a proper seal. Avoid using pliers or other tools that could damage the lines. If you're unsure how to disconnect them, refer to your repair manual or consult a professional.
3. Disconnect Electrical Connections: There will be various electrical connectors, such as for the fuel level sender. Carefully disconnect these connectors.
4. Disconnect the Fuel Tank Filler Neck: The filler neck connects the fuel tank to the gas cap opening. Disconnect this.
5. Support the Fuel Tank: Securely support the fuel tank. Use jack stands under the rear axle or a fuel tank support strap.
6. Remove Fuel Tank Straps/Bolts: Locate the straps or bolts securing the fuel tank to the vehicle. Carefully remove these. The number and location of these fasteners will vary depending on your model.
7. Lower the Fuel Tank: Carefully lower the tank, guiding it clear of any obstructions. A fuel tank hoist will greatly simplify this step.
8. Complete Removal: Once the tank is clear, carefully move it to a safe location.
Reassembly:
Follow the steps in reverse order. Ensure all connections are secure and all fuel lines are properly connected and free of leaks.
Important Considerations:
* Properly dispose of any spilled fuel. Gasoline is a hazardous material.
* Never work on the fuel system with a lit cigarette or open flame.
* If you're uncomfortable performing this task, seek professional help from a qualified mechanic. This is not a beginner-level repair.
This is a general guide; specifics may vary depending on your exact F-150 model and trim. Always consult your vehicle's repair manual for precise instructions and safety precautions. Improperly handling fuel lines and a fuel tank is extremely dangerous. If you have any doubt about your abilities, seek professional assistance.
