Ford BR3Z-9002-B Fuel Tank Assembly

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Relieve the system fuel pressure. Disconnect the cable from the negative terminal of the battery. Unless the vehicle has been driven far enough to completely empty the tank, it's critical to siphon the residual fuel out before removing the tank from the vehicle because the tank is quite heavy when filled with fuel. You can siphon some, but not all, of the fuel from the tank through the fuel filler neck hose. Remove the fuel tank filler neck cap and insert a siphon hose into the filler neck, pushing it down until it bottoms out inside the fuel tank, then siphon out as much fuel as possible into an approved fuel container. Due to the shape of the fuel tank, you probably won't be able to siphon all the fuel through the fuel filler neck. You might encounter some resistance when the siphoning hose reaches the fuel tank because it must go through the filler pipe check valve, but the hose will push past the check valve as long as the hose diameter isn't too big. When done siphoning, leave the siphon hose in place until the fuel tank is removed to avoid damaging the check valve. Siphon out the rest of the fuel later. Remove the rear seat cushion. Remove the fuel pump module and fuel level sensor access covers. Disconnect the electrical connector and the fuel tube quick-connect coupling from the fuel pump module. Disconnect the electrical connector from the fuel level sensor. Remove the fuel pump module and the fuel level sensor, then insert a siphon hose through each opening to siphon out as much fuel as possible. Raise the rear of the vehicle and support it securely on jackstands. Remove the intermediate exhaust pipe and the driveshaft. If working on a convertible model, remove the rear support braces. Detach the pin-type taillight harness retainers from the outer edge of the fuel tank by inserting a screwdriver between the tank flange and the clip to pry it loose. Loosen the hose clamp screw to disconnect the fuel filler neck hose from the fuel tank. Support the fuel tank securely, having at least one assistant standing by to help until the tank is on the floor. Remove the two fuel tank strap retaining bolts to detach the fuel tank straps. Lower the tank just far enough to access the fuel tank EVAP tube quick-connect fitting and disconnect this fitting. Remove the fuel tank strap retainer pins and straps. With the help of at least one assistant to steady the tank, carefully lower it to the floor. Installation is the reverse of removal.

Be especially careful inside a garage where a gas-type appliance is located, because it could cause an explosion.