Ford 6R3Z-9275-AA Fuel Tank Sender Assembly

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Relieve the system fuel pressure, then disconnect the cable from the negative battery terminal. Remove the rear seat cushion and the fuel pump module access cover on the left by carefully prying it loose from the floorpan. Disconnect the fuel pump module electrical connector and the fuel supply line quick-connect fitting by depressing the release button and pulling the fuel line out of the coupling. Using a hammer and a brass punch, loosen the fuel pump module lock ring by turning it counterclockwise, and fully unscrew it once loose. Before removing the fuel pump module from the fuel tank, mark its relationship to the tank. Lift the fuel pump module assembly enough to access the quick-connect coupling for the crossover tube connected to the underside of the assembly, disconnecting it in the same manner as the previous fitting. After disconnecting the crossover tube, carefully lift the fuel pump module assembly out of the fuel tank. Remove and discard the old O-ring type seal for the fuel level sensor. If planning to reinstall the original fuel pump unit, inspect the condition of the fuel inlet strainer, cleaning it if slightly dirty or replacing the pump if it is obstructed. Clean the fuel pump mounting flange and the tank mounting surface, particularly where the O-ring type seal is installed, using a new seal and applying a thin coat of heavy grease to hold it in place during installation. After installing the fuel pump assembly in the fuel tank, ensure the alignment arrows on the pump mounting flange and the top of the fuel tank are aligned, with installation otherwise being the reverse of removal.

Relieve the system fuel pressure, then disconnect the cable from the negative battery terminal. Remove the rear seat cushion and take off the fuel level sensor access cover located on the right. Disconnect the fuel level sensor electrical connector. Using a hammer and a brass punch, loosen the fuel level sensor lock ring by turning it counterclockwise, and when it is loose enough, fully unscrew it. Before removing the fuel level sensor from the fuel tank, mark its relationship to the tank. Lift the fuel level sensor to access the quick-connect coupling for the crossover tube connected to the underside of the sensor assembly, and disconnect the crossover tube's quick-connect fitting by depressing the release button and pulling the fuel line out. After disconnecting the crossover tube, carefully lift the fuel level sensor out of the fuel tank, angling it as necessary to protect the float and float arm from damage. Remove and discard the old O-ring type seal, then clean the fuel sensor mounting flange and the tank mounting surface, ensuring to use a new O-ring type seal with a thin coat of heavy grease to hold it in place during installation. After installing the fuel sensor in the fuel tank, ensure the alignment arrows on the sensor mounting flange and the top of the fuel tank are aligned, and complete the installation by reversing the removal steps.

a) The fuel delivery line or a quick-connect fitting might be leaking. b) A fuel injector (or injectors) may be leaking. c) The fuel pump might be defective.