Fuel Tank Removal and Installation
Removal and InstallationWARNING: Do not smoke or carry an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury.
1. Drain the fuel tank. For additional information, refer to FUEL TANK DRAINING.
2. Remove the left rear wheel. For additional information, refer to WHEEL AND TIRE.
3. Remove the rivets and the fuel tank filler tube shield.
4. Disconnect the fuel tank filler hose and the fuel tank filler vent hose from the fuel filler tube.
5. Remove the muffler. For additional information, for 2.0L Zetec engine, refer to MUFFLER AND TAILPIPE or for 3.0L (4V) engine, refer to MUFFLER AND TAILPIPE.
6. On 4WD vehicles, remove the driveshaft. For additional information, refer to DRIVESHAFT.
7. Remove the differential mounting bracket-to-subframe mounting bolt.
8. Remove the rear differential mass damper.
1. Remove the bolts.
2. Remove the rear differential mass damper.
9. Disconnect the electrical connector.
10. Using a suitable jack, support the rear differential assembly.
11. Position the axle assembly rearward.
1. Remove the differential-to-bracket bolts.
2. Loosen the differential mounting bracket-to-subframe mounting bolts, rotate the brackets and position the axle assembly rearward.
12. Use a suitable jack to support the fuel tank.
13. Disconnect the vapor hose.
14. Disconnect the pin-type retainer from the fuel tank strap and position the parking brake cable aside.
NOTE: For 4WD vehicles, it will be necessary to disconnect a wiring harness clip from the fuel tank strap.
15. Remove the bolts and the fuel tank straps.
16. Lower and remove the fuel tank.
17. To install, reverse the removal procedure.
1. Use the Heavy-Duty Riveter to install the rivets.