Here's a general outline of the steps involved. Remember, this is a simplified overview and may not cover every variation or potential issue you might encounter:
I. Preparation:
1. Safety First: This is paramount. Work in a well-ventilated area away from ignition sources. Disconnect the negative battery terminal. Obtain safety glasses, gloves, and potentially a respirator.
2. Gather Tools and Materials: You'll need jack stands, jack, wrenches (various sizes), sockets, fuel line disconnect tools, a drain pan, new fuel tank straps, possibly new fuel lines, new tank gasket (if needed), rags, and possibly a fuel pump access panel removal tool.
3. Empty the Fuel Tank: This is absolutely crucial. Drive the truck until nearly empty. You can also siphon the remaining fuel, but do so carefully and follow all safety regulations.
4. Raise the Truck: Securely jack up the truck and place it on jack stands. Ensure the truck is stable and will not move.
II. Removing the Old Tank:
1. Disconnect Fuel Lines: This is potentially the most dangerous part. Carefully disconnect the fuel lines using the appropriate tools. Note which line goes where for reinstallation. Plug the lines to prevent fuel spillage.
2. Disconnect Electrical Connections: Disconnect the fuel sending unit and any other electrical connectors attached to the tank.
3. Remove the Fuel Tank Straps: Loosen and then remove the straps securing the tank to the vehicle's frame.
4. Lower the Tank: Carefully lower the fuel tank. It's heavy and may require assistance. Have a drain pan ready to catch any remaining fuel.
III. Installing the New Tank:
1. Inspect the New Tank: Make sure the new tank is undamaged and comes with all necessary gaskets and hardware.
2. Install the New Gasket: If necessary, install a new gasket onto the tank's mounting flange.
3. Install the Tank: Carefully position the new tank in its place.
4. Secure the Tank Straps: Tighten the tank straps securely, ensuring the tank is level and stable.
5. Reconnect Electrical Connections: Reconnect all electrical connections carefully.
6. Reconnect Fuel Lines: Reconnect the fuel lines, ensuring a tight and secure connection. Double-check all connections for leaks.
7. Lower the Truck: Carefully lower the truck from the jack stands.
IV. Post-Installation:
1. Check for Leaks: Thoroughly inspect all fuel line connections for leaks.
2. Reconnect Battery: Reconnect the negative battery terminal.
3. Start the Engine: Start the engine and check for any fuel leaks or unusual noises.
4. Test Drive: Take the truck for a short test drive to ensure everything is working correctly.
Important Considerations:
* Fuel Vapor: Fuel vapors are highly flammable and potentially explosive. Work in a well-ventilated area.
* Static Electricity: Static discharge can ignite fuel vapors. Take appropriate precautions.
* Fuel Pump: The fuel pump may be integrated into the tank. If so, this will require additional steps for removal and installation.
* Professional Help: If you're not comfortable performing this task, it's best to have a qualified mechanic do it.
This is a simplified guide. Consult a repair manual specific to your 1995 Ford F-150 for detailed instructions, torque specifications, and safety precautions. Failure to follow proper procedures could result in injury or damage. Remember safety first!
