NOTE: There are two methods of getting to the fuel tank, the first and easiest is to remove the bed of the truck, then you do not have to remove the fuel tank. Below are the intructions if you choose to remove the fuel tank.

Removing the Fuel Tank

1. Siphon out as much fuel as possible from the tank if the tank is not already near empty. Use a suction pump and deposit the fuel into a gasoline can.

2. Disconnect the fuel pump's electrical connector, which is behind a splash shield on the frame rail below the driver's door (unbolt the shield with a wrench). Start the engine and wait for it to stall, depressurizing the fuel system.

3. Disconnect the battery's negative cable in the engine compartment.

4. Loosen the lug nuts for the wheel closest to the fuel tank--usually the left wheel--using your tire iron, raise the rear end of the truck onto jack stands and remove the wheel. Disconnect the tank's skid plate if one is installed; remove its nuts with a wrench.

5. Disconnect the fuel and evap lines near the front and rear of the tank; these lines use quick-connect couplings. Loosen the clamp for the filler neck hose with pliers or a screwdriver and pull the neck off the tank.

6. Unbolt the tank's support straps with a wrench while another person holds the tank up, or raise a floor jack under the tank to support it. Lower the tank until you can access the electrical connectors and filler neck vent hose.

7. Disconnect the hose for the filler neck vent by prying its clamp loose and then unplug the electrical connectors, then lower the tank away from the truck

Removing the Fuel Pump

1. Disconnect all the fuel and EVAP lines from the top end of the module, which should all use quick-connect couplings.

2. Loosen the module's lock ring, tapping it in a counterclockwise direction with a hammer and brass punch, then unscrew and remove the ring once it is loose enough.

3. Lift the fuel pump module out of the tank until you can reach the EVAP line connected to the underside of the module. Disconnect this line at its quick-connect coupling and then lift the module completely out of the tank.

4. Pull out and discard the O-ring surrounding the mount hole for the module on the fuel tank

Installation

1. Install a new O-ring around the fuel tank's mounting surface for the fuel
pump module.

2. Connect the fuel pump module to the evap line in the fuel tank using the
quick-connect coupling, then lower the module into the tank. Install the locking
ring and screw it in clockwise until it lodges into the recesses in the tank.

3. Re-connect the appropriate fuel and evap lines to the top of the pump module with the quick-connect fittings, and then raise the tank into position on the truck

4. Plug in the electrical connector to the tank and connect the filler neck vent hose with its clamp and then bolt the tank straps in place with the wrench. Connect the fuel and evap lines at both ends of the tank along with the filler neck and its clamp.

5. Attach the tank's skid plate if necessary with its nuts and the wrench, then lower the truck off the jack stands. Reconnect the fuel pump electrical connector and the battery cable, then refill the tank with the fuel.

 

A couple of things worth noting:

1. The filler tube and the breather pull out of the tank--remove the breather from the filler and attach it to the tank before you replace the tank. If you undo the fitting at the fuel cap it makes it much easier

2. The fuel line is very stiff so undo the clip on the cross member to give you more play.

Other than that and some cramped working conditions it is possible to replace the unit--getting the replacement though is a bit of a trick Ford doesn't make them anymore and after market doesn't know the difference between the center tank unit and the rear one--the rear one is shallower..