1994 Bronco/Econoline/F-Series

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1 Page 1 of 8 Section 10-01A: Fuel Tank, Filters, Lines and Electric Fuel Pump, Gasoline Engines REMOVAL AND INSTALLATION 1994 Bronco/Econoline/F-Series Workshop Manual Fuel Tank Steel Midship Fuel Tank, F and F-Super Duty NOTE: As there are different midship fuel tanks which are removed and installed essentially the same way, follow steps and refer to appropriate illustration for details. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 1. Disconnect battery ground cable (14301). 2. Using Rotunda Fuel Storage Tanker or equivalent, drain fuel tank. Drain both fuel tanks on dual-tank vehicles. 3. Raise vehicle on hoist. 4. If equipped with skid plate, remove fasteners and remove skid plate assembly. 5. Loosen clamps and disconnect fuel tank filler pipe and overflow hose at fuel tank. 6. Position suitable jack under fuel tank. 7. Remove nuts and bolts and lower fuel tank support straps (9092). If necessary, turn fuel tank support strap approximately 30 degrees and remove. 8. Lower fuel tank enough to gain access to fuel connections. 9. Disconnect electrical connector from fuel tank sending unit and pump. 10. Disconnect fuel vapor hose(s) from port valve(s). If equipped, remove vent hose from clip on frame. 11. Disconnect fuel supply and return lines according to instructions for push connectors in this section. 12. Remove fuel tank from vehicle. For installation, follow removal procedures in reverse order. Refer to the following illustration for tightening specifications. Midship Fuel Tank Installation, F and F-Super Duty Chassis Cab, 116- and 138-Inch Wheelbase Fuel Tank 2 9K014 Shield Assembly

Page 2 of 8 3 9240 Insulator Upper 4 9054 Fuel Tank Support Strap 5 9057 Strap, Rear 6 N802253-S2 Bolt 7 N620481-S Nut 30-41 Nm (22-30 Ft-Lb) 8 5005 Frame 9 9A147 Skid Plate Heat Shield 10

2 Page 2 of Insulator Upper Fuel Tank Support Strap Strap, Rear 6 N S2 Bolt 7 N S Nut Nm (22-30 Ft-Lb) Frame 9 9A147 Skid Plate Heat Shield 10 N S20 Bolt 11 N S2 Nut Nm (12-17 Ft-Lb) 12 N S2 Bolt Nm (12-17 Ft-Lb) 13 N S2 U-Nut 14 9C038 Bracket 15 N S2 Bolt Nm (12-17 Ft-Lb) Crossmember, Fuel Tank 17 N S2 Bolt 17A N S56 Nut Nm (26-36 Ft-Lb) Midship Fuel Tank Installation, F and F-Super Duty Chassis Cab Fuel Tank Fuel Tank Support Strap Strap, Rear 4 9A148 Skid Plate 5 9K014 Shield Frame 7 N S2 Bolt 8 N S2 Bolt Nm (12-17 Ft-Lb) 9 N S2 U-Nut 10 N S2 Nut Nm (12-17 Ft-Lb) Insulator, Upper

3 Page 3 of 8 12 N S100 U-Nut 13 N S2 Bolt Nm (23-30 Ft-Lb) 14 N S2 Nut Nm (23-30 Ft-Lb) Bracket 16 N S2 Bolt 17 N S2 Nut Nm (17-20 Ft-Lb) Midship Fuel Tank, E NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 1. Disconnect battery ground cable. 2. Raise vehicle on hoist. 3. Push rear valve down and twist 90 degrees to remove. 4. Using Rotunda Fuel Storage Tanker or equivalent, drain fuel tank. 5. Loosen clamps and disconnect fuel tank filler pipe hose and overflow hose at fuel tank filler pipe. 6. Disconnect electrical connector from fuel tank sending unit and pump. 7. Position suitable jack under fuel tank. 8. Remove two nuts and lower straps. If it is necessary to remove fuel tank support straps, turn T-bolts which are part of the fuel tank support straps 90 degrees and take out. 9. Lower fuel tank enough to gain access to fuel connections. 10. Disconnect fuel vapor hose from port valve. Remove vent hose from clip on frame of 5.8L and 7.5L vehicles. 11. Disconnect fuel supply and return lines according to instructions for push connectors in this section. 12. Remove fuel tank from vehicle. 13. Loosen clamps and remove fuel tank filler pipe and overflow hoses from fuel tank. For installation, follow removal procedures in reverse order. Refer to the following illustration for tightening specifications. Install filler hose with stripes in line with dimples on tank. Midship Fuel Tank Installation, E Item Part Number 1 9B212 Shield, Fuel Tank Rear 2 N S2 Screw Nm (8-10 Ft-Lb) Description 3 9K014 Shield Assembly, Fuel Tank 4 N S2 Screw and Washer 6-7 Nm (53-61 In-Lb)

4 Page 4 of Pushpin 6 9K014 Shield Assembly, Fuel Tank 7 9A017 Fuel Tank Support Fuel Tank (Midship) Fuel Tank Support Strap 10 N S2 Nut and Washer Assembly Nm (13-16 Ft-Lb) 11 9B023 Insert, Fuel Tank Vent Tube Frame Aft-of-Axle Fuel Tank F and F-Super Duty CAUTION: Care must be taken when installing the fuel tank to make sure the fuel lines do not become kinked. 1. Raise the rear of the vehicle. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 2. To avoid electrical sparking at the fuel tank, disconnect battery ground cable. Then disconnect the connector from fuel tank sending unit and pump near the fuel tank. 3. Using Rotunda Fuel Storage Tanker or equivalent, drain fuel tank. Drain both fuel tanks on dual tank vehicles. 4. Disconnect the fuel line push-connect fittings at the fuel tank sending unit and pump. 5. Loosen the clamp on the fuel tank filler pipe. Disconnect the fuel tank filler pipe by pulling along the rubber inner tube from the filler neck. 6. If removing the metal-type fuel tank, support the fuel tank and remove the bolts attaching the fuel tank support strap to the frame. Carefully lower the fuel tank and disconnect the vent tube(s) from the vapor emission control valve in the top of the fuel tank. Finish removing the fuel tank filler pipe and fuel tank filler pipe vent hose if not possible in Step 5. Remove the fuel tank from under the vehicle. 7. If removing the plastic-type fuel tank, support the fuel tank and remove the bolts attaching the combination skid plate and tank support to the frame. Carefully lower the fuel tank and disconnect the vent tube(s) from the vapor emission control valve in the top of the fuel tank. Complete removing the fuel tank filler pipe if not possible in Step 5. Remove the skid plate and fuel tank from under the vehicle. Disassemble the skid plate from the tank. For installation, follow removal procedures in reverse order. Use a thread adhesive (such as Loctite TM or equivalent) on metal fuel tank attaching nuts and bolts. Refer to the following illustrations for tightening specifications. When installing the fuel tank, grasp the three hoses about 300mm (12 inches) forward of the crossmember. Hold the hoses taut while installing the fuel tank. This will prevent the fuel lines from becoming kinked which will cause restricted fuel flow. Steel Aft-of-Axle Tank Installation, F , 116-, 113-, 138- and 115-Inch Wheelbase Fuel Tank 2 9A017 Fuel Tank Support Insulator 4 N S100 Bolt Fuel Tank Support Strap S362 Nut 7 9K015 Stone Shield (RH) 8 9C045 Stone Shield (LH) S2 Washer 10 N S2 Nut (28-36 Ft-Lb) Plastic Aft-of-Axle Tank Installation, F-350, and Inch Wheelbase

5 Page 5 of 8 Item Part Number Description 1 9A307 Fuel Tank Sending Unit Locking Retainer Ring Nm (40-55 Ft-Lb) Fuel Tank Support Strap 3 W S2 Spring Washer 4 9B227 Hose and Valve Assembly 5 9B076 Seal Fuel Tank 7 N Nut, M Nm (25-34 Ft-Lb) 8 9A148 Skid Plate 9 N S2 Bolt M S2 Nut 7-10 Nm (5-8 Ft-Lb) Bolt M Crossmember 13 N S2 Bolt Nm (28-36 Ft-Lb) S2 Screw Nm (7-11 Ft-Lb) 15 9A032 Shield Frame 17 9B100 Shield Aft-Of-Axle Fuel Tank, F-Super Duty Motorhome Chassis Refer to the following illustration. F-Super Duty Motorhome Chassis, Aft-of-Axle 75-Gallon Tank

6 Page 6 of Rear Frame Crossmember 2 N S2 Bolt Nm (15-24 Ft-Lb) 3 N S2 Bolt Nm (44-66 Ft-Lb) 4 N S2 Bolt Nm (15-24 Ft-Lb) 5 N S2 Bolt Nm (59-88 Ft-Lb) 6 N S2 Nut Nm (20-25 Ft-Lb) 7 N S160 Nut Nm (44-67 Ft-Lb) Fuel Tank Fuel Tank Support Strap 10 9B007 Fuel Tank Modification Shield and Pipe Kit 11 W S2 Screw Nm (15-22 Ft-Lb) 12 N80616-S Washer S36 Nut 14 9H307 Fuel Tank Sending Unit and Pump Gasket Aft-of-Axle Fuel Tank, E-Series Cutaway CAUTION: On 55-gallon fuel tank, loosen strap nuts enough to relieve tension on fuel tank support strap. (If tension is not relieved lower support arms will deform upward, making installation difficult.) NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 1. Disconnect battery ground cable. 2. Using Rotunda Fuel Storage Tanker or equivalent, drain fuel tank. 3. Raise vehicle on hoist. 4. Position suitable jack under fuel tank. 5. Remove screws and nuts from fuel tank fuel tank modification shield and pipe kit (9B007). On 55-gallon fuel tank, fuel tank modification shield and pipe kit does not have to be removed to lower fuel tank. 6. Loosen clamps and disconnect fuel tank filler pipe and overflow hoses at fuel tank filler pipe end. 7. On 35- and 55-gallon tanks, upper tank straps do not have to be removed to lower tank. Remove nuts and bolts which secure lower supports to frame. 8. Lower fuel tank. 9. Disconnect fuel tank sending unit and pump electrical connector. 10. Disconnect fuel vapor hose from fuel vapor valve (9B593). Remove short vapor vent hose (5.8L and 7.5L) from grommet in frame. 11. Disconnect fuel supply and return lines according to instructions for push connectors in this section.

7 Page 7 of Remove fuel tank from vehicle. For installation, follow removal procedures in reverse order. Refer to the following illustration for tightening specifications. Aft-of-Axle Fuel Tank Installation, E-Series Cutaway Item Part Number Description 1 9A017 Fuel Tank Support Spacer, Fuel Tank Bracket 3 N S2 Bolt Nm (65-87 Ft-Lb) 4 N S2 Nut Nm (44-59 Ft-Lb) 5 N S2 Bolt 6 9A032 Heat Shield, Fuel Tank Fuel Tank 8 N S2 Nut and Retainer 9 N S2 Bolt Nm (65-87 Ft-Lb) 10 N S2 Nut 11 9H307 Fuel Tank Sending Unit and Pump Frame Aft-of-Axle Fuel Tank, Bronco NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy. 1. To avoid electrical sparking at the fuel tank, disconnect battery ground cable. 2. Using Rotunda Fuel Storage Tanker or equivalent, drain fuel tank. 3. Raise the rear of the vehicle. 4. Loosen the clamp on the fuel filler pipe hose at the fuel tank filler pipe and disconnect the hose from the fuel tank filler pipe by pulling along the internal fuel tube from the tank filler neck. 5. Disconnect fuel tank sending unit and pump connector. 6. Disconnect fuel line push connectors and fuel vapor lines as outlined in this section. 7. Support the fuel tank and remove the fuel tank support bracket bolts or skid plate bolts. Remove the fuel tank support or skid plate attaching nut at each tank mounting fuel tank

8 Page 8 of 8 support strap. Lower the fuel tank supports (9053), and lower the fuel tank enough to gain access to the fuel tank vent hose. 8. Remove the fuel tank from under the vehicle. For installation, follow removal procedures in reverse order. Refer to the following illustration for tightening specifications. Aft-of-Axle Fuel Tank Installation, Bronco (4x4) Fuel Tank Support Strap Fuel Tank 3 N S100 Bolt S2 Washer 5 N S2 Nut Nm (28-36 Ft-Lb) 6 9A017 Fuel Tank Support S36 Nut 8 9B227 Hose and Valve Assembly, Fuel Vapor Return 5.0L Engine 9 9C987 Hose and Valve Assembly, Fuel Vapor Return 5.8L Engine 10 9B076 Seal, Separator Fuel Vapor

REMOVAL AND INSTALLATION

310-00-1 Fuel System 310-00-1 REMOVAL AND INSTALLATION Fuel Tank and Filler Pipe Special Tool(s) Fuel Tank Drain Hose 310-F013 2. NOTE: Steps 2 through 5 are only necessary if servicing the fuel tank or