Ford Ranger Fuel Tank Removal

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The fuel tank on your Ford Ranger may develop problems that make it necessary to remove or replace it. Some tank leaks, holes or contamination issues can only be fixed with the tank off the vehicle. However, whether you are taking the fuel tank for repairs or replacing it, you can save some money by removing, re-installing or replacing the tank yourself. The next steps will guide you through the process. Still, choose a safe place to work and take the necessary precautions to avoid an accident. Remember that fuel is highly combustible.

Relieving the Fuel System Pressure

  • Start by relieving the fuel pressure in the system. Loosen the fuel filler cap and disconnect the ground battery cable. Now you can connect a fuel pressure gauge to the test port valve located on the fuel rail, near the fuel injectors. Then insert the gauge bleed hose into a glass container. Wrap a shop rag around the port valve and open the gauge valve to relieve the pressure.

    You have the alternative of wrapping a shop rag around the port valve and press the valve stem with a small screwdriver. You need to make sure the engine is completely cool to the touch, however, to avoid any bleeding fuel from reaching a hot engine part or component, which may cause a fire or explosion.

Removing the Tank

  • Empty the fuel tank if necessary. You can use a hand siphon pump and an approved container for this. Then raise the rear of your Ford Ranger and support it on jack stands. On some models, you will have to remove a skid plate to gain access to the fuel tank.

    Loosen the tank fill hoses from the pipes and support the tank with a floor jack. Now remove the tank straps and lower the tank a few inches so that you can reach and disconnect the fuel and vapor lines. Then unplug the fuel pump electrical connector and disconnect the vapor line from the rear of the tank. Make sure there are no remaining lines connected. Then finish lowering the tank and remove it from the vehicle.

Installing the Tank

  • Support the tank on the floor jack and raise it a few inches to connect the front and rear fuel and vapor lines. Then plug the fuel pump electrical connector. Once you are sure the lines are properly connected, raise the tank into position, install the tank straps and remove the floor jack.

    Install and tighten the fill hoses, lower the vehicle and fill the fuel tank. Connect the ground battery cable, start the vehicle and make sure there are no fuel leaks. Then turn off the engine.

References

  • Ford Ranger Pick-ups 1993 thru 2008 Haynes Repair Manual; Eric Jorgensen, Alan Ahlstrand and John H. Haynes; 2009
  • Modern Automotive Technology; James E. Duffy; 2003
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