Ford 9L3Z-9A299-D Fuel Tank Sender Assembly

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Relieve the system fuel pressure and disconnect the cable from the negative battery terminal. Remove the fuel tank, ensuring to clean the tank surface thoroughly around the fuel pump module before removal to prevent dirt or debris from entering. Disconnect the fuel and EVAP line quick-connect couplings from the fuel pump/fuel level sensor. Using a hammer and a brass punch, loosen the lock ring that secures the fuel pump/fuel level sensor, then fully unscrew it. Lift the fuel pump/fuel level sensor assembly enough to access the quick-connect coupling for the EVAP line on the underside, disconnect it, and carefully lift the assembly out of the fuel tank, angling it as necessary to protect the float arm and float from damage. Remove and discard the old O-ring type seal. If reinstalling the original fuel pump unit, inspect the fuel inlet strainer; if slightly dirty, scrub it gently and rinse with clean solvent, but if too dirty to clean, replace the pump, as the strainer is a permanent part of the pump. Clean the fuel pump mounting flange and the tank mounting surface, especially where the O-ring type seal is installed. Use a new O-ring type seal and apply a thin coat of heavy grease to hold it in place during installation. After installing the fuel pump/fuel level sensor assembly in the fuel tank, ensure the alignment arrows on the pump mounting flange and the top of the fuel tank are aligned. Installation is otherwise the reverse of removal.

Remove the heat shrink tubing from the electrical connector (specifically from the fuel level sensor electrical connector) and disconnect the spade-type connector.