Ford AL8Z-9002-C Fuel Tank Assembly

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There is no fuel tank drain plug, so it's easier to remove the fuel tank when it's nearly empty. If that's not possible, try to siphon out the fuel in the tank before removing it. Relieve the fuel system pressure and disconnect the cable from the negative battery terminal. Working inside the vehicle, disconnect the electrical connectors from the fuel pump/fuel level sending unit module and from the fuel pressure sensor. Also disconnect the fuel line(s); some models have two, others only have one. If there's still a lot of fuel in the tank, siphon or hand pump the remaining fuel from the tank now. You can siphon the fuel out of the tank through the hole in the top of the tank for the fuel pump/fuel level sending unit module, or through the fuel filler neck or through the fuel filler neck pipe, after you have disconnected the fuel filler neck hose from the fuel tank. Loosen the left rear wheel lug nuts, raise the vehicle and place it securely on jackstands, then remove the left rear wheel. Drill out the rivets that attach the fuel filler hose shield and remove the shield. Disconnect the fuel tank filler hose and the fuel tank filler vent hose from the fuel tank filler tube. On 4WD models, remove the driveshaft, remove the differential mounting bracket to subframe mounting bolt, remove the differential to bracket bolts, loosen the differential mounting bracket to subframe mounting bolts, rotate the brackets and position the axle assembly to the rear. Support the fuel tank with a transmission jack or a floor jack. If you're going to use a floor jack, place a sturdy piece of plywood between the jack head and the tank to protect the tank. Disconnect the EVAP hose and disconnect the pin type retainer that attaches the parking brake to the left fuel tank strap.On 4WD models, disconnect the wiring harness clip from the rear of the left fuel tank strap. Raise the vehicle and support it securely on jackstands. Remove the muffler and resonator. On 4WD models, remove the rear driveshaft. Detach the filler hose from the fuel tank and disconnect the parking brake retainer and the wiring harness retainer from the left fuel tank support strap. Place a floor jack under the fuel tank with a piece of plywood to protect the tank. Raise the jack enough to take weight off the support straps. Remove the fuel tank strap bolts and swing the fuel tank straps down and out of the way. Lower the tank enough to have a look at the top of the tank and unclip or detach any remaining cables, hoses or lines. Then, lower the tank the rest of the way. Installation is the reverse of the removal procedure. Note: Replace the O-ring seal whenever the module is removed. After you've reconnected the battery, the Powertrain Control Module (PCM) must relearn its idle and fuel trim strategy for optimum driveability and performance.

You can siphon the fuel out of the tank through the hole in the top of the tank for the fuel pump/fuel level sending unit module, or through the fuel filler neck or through the fuel filler neck pipe after disconnecting the fuel filler neck hose from the fuel tank.

A professional with experience in this critical and potentially dangerous work.

Explosive fumes can still remain and ignite during tank repair.