Ford 4L3Z-9002-DA Fuel Tank Assembly

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It is necessary to pump out the fuel left in the tank before taking out the fuel tank as this may be large and heavy when full. Start with reducing the fuel pump pressure and the removing the negative terminal of the battery. Lose the lug nuts and left rear wheel, then jack the car up properly and use jack stands to safely support the car, and finally, remove the wheel altogether. If so fitted, remove the skid plate by undoing the nuts that hold the plate on the bike. Remove the quick-connect couplings for the fuel supply and EVAP canister purge line at the front side of the fuel tank and the couplings for the EVAP vent line and canister purge line at the rear side. Go down to the metal fuel filler neck pipe at the left rear wheel channel, remove the hose clip and take off the fuel filler neck hose. If there is still several gallons in the tank, drain it through the filler neck hose; keep the siphon hose in place until the tank is pulled so that the check valve won't be bent. Assist in supporting the tank and then take out the bolts of the fuel tank straps front and rear they will drop down and come out of the cross members. Ease down the tank substantially enough that you can get a look at the electrical connector and the hose that connects directly to the filler neck vent pipe into the tank, being very careful not to bend the connectors or the hose. The next step is to remove the vent hose and cut the clamp off, the last step is disconnect all the electrical connectors of the fuel pump/fuel level senor and the Fuel Tank Pressure sensor. Assisted, lower the tank down to the floor, and installation is going to happen in the exact opposite method to the removal process.

The fuel tanks are made of plastic and are not repairable.