While I've never had the pleasure of changing the tank on my Ford, I'd say make sure the tank is as empty as you can get it, disconnect the filler neck and vapor hose from the tank, remove the straps that hold the tank up using a floor jack or something that will control how quickly it comes down, after lowering it no more than you have to disconnect the electrical connector(s) to the fuel pump/sender assembly. Then lower it the rest of the way. Reverse for install.
In automotive since 1973, Ford from 1992 to 2006 ex-Ford dealership employee
Welcome to FTE gstidard. I am assuming you want to replace the tank because it is leaking. If the leak is not too bad then it is best to run the tank down until the gas light comes on (as Ron said). Makes it so much easier. You will also want to spray the 2 bolts that hold the straps on. I recommend PB Blaster. Also an impact gun makes it a little easier to remove the bolts.
Do everything Ron said. Also there are a couple things on top of the tank towards the rear of the truck (not sure what they are called). Use some channel locks to remove them. They get transferred to the new tank. They also twist off. They are hard to put back in. It will be MUCH easier to put back in if you put a little oil on the rubber o-ring.
I didn't remove the fuel lines from the pump. I left them on and unscrewed the pump from the tank and let it hang. Seemed like it would be easier (it was). You will also probably need to replace the clamps that hold a couple hoses onto the tank. If you live in a salt area they will be rusted beyond belief.
Also, if you live in the salt belt you will want to replace your tank straps since you have it all apart. They are about $35-50 or so. They will probably be really rusty and possibly fail soon (I just replaced the ones on my Dad's 2001 a couple weeks ago).
One more tip: You can buy Rocker panel stone guard for about $10 a can or so. I sprayed down the tank with it as well as the straps and let it dry. Just a little protection from the rust.
I just replaced the tank on my 2001 a few weeks ago so if you have any questions do not hesitate to ask.
even with the fuel light on mine still had 5 gallons in it. a second person makes it a lot easier. mine has a skid plate that needs to be taken off first. i disconnected the filler neck by the frame where the rubber hose meets the metal line. then the 2 breathers. they were kinda seized on. wd helped alot. next i used a quick disconnect tool for the 2 lines from the pump. that black plastic thing in the back that says push and turn is a pressure sensor that costs $96 from the dealer, its gonna be hard not to break it. you can release the plug with a flathead then try to remove it from the tank. i broke mine and tried to get another for the junk yard i work at and i broke about 5 before i got a new one. putting it back in was easier. only took about an hour for me and a buddy to pull and like 45 mins to reinstall.
all the advice I got on replacing the fuel tank on my 2000 f150 was a great help for myself. I did in up breaking one of the two sensors on top of the tank $87.00 but all & all it took me 2.5 hours with a coffee break in between so thankyou toall who replyed.
The hardest part I found is once the tanks unbolted all my wiring connections had sand and junk built up in them and didn't want to let go. That's how I broke my FTPS. Def get a second person. The tank has to come down and back to clear one of the frame cross members so a person can do better then a 2nd floor jack. Try and empty out the tank the best you can but its doable if there's gas in the tank just takes time and care (mine has 15 gallons or so when I did mine cause I love the challange) . Lots of PB blaster for the hose clamps. Don't forget the hose clamp that acts as a support for the filler neck which attaches to the bed of the truck I almost missed that one.
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