The steps shown in the article will cover 1998 to 2004 Mustangs. There were a few differences throughout this year's range, but the core removal process is the same.
You’ll find a few differences: 1998 Mustangs still utilized a return-style fuel system, so you’ll have an extra line to disconnect. You’ll also find that some of the EVAP hoses will be different. Lastly, IRS-equipped cars have little working space because of the IRS subframe.
Before we get started with the removal process, I would like to go ahead and make a note of a few things.
The first one will be that whenever you remove the fuel tank, make sure you don’t break the tip of the filler neck. We’ve seen this happen quite a few times on these cars, and it just so happens the tip of the filler neck is broken on this car.
The second thing that you need to do is make sure that you purchase a new filler neck grommet, no matter what! Regardless of how careful you are, these can tear easily, and it’s best to spend a little bit of money on a brand-new one.
Tap Here To Order A New Fuel Filler Neck Grommet
Finally, get as much gasoline out of your tank as possible. You can take your car out for a drive or go a different route... (This is just a suggestion, so don't be upset if you get in trouble)
Tools Needed
- Safety Glasses & Gloves
- Compressed Air
- General Shop Supplies
- Jacks & Jack Stands
- Drain Pan
- Fuel Link Disconnect Tools
- 1/4", 3/8", & 1/2" Socket Sets & Extensions
- Screwdriver Set & Prybars
Removal Steps
- Open the hood and disconnect the negative battery cable. Locate the Shrader valve on the fuel rail. Remove the cap.
- Have some rags ready, and use a small flathead screwdriver or similar tool to depress the valve. This will relieve any pressure from the fuel system.
- Now you can support the car via a lift or get it as high and as safe as possible if you’re working off jack stands. Position a drain pan underneath the fuel filter.
- Remove the two safety clips from the hard lines and filter.
- Loosen the clamp with an 8mm socket and position it out of the way. Remove the filter from the bracket.
- Use a fuel line disconnect tool and disconnect the line from the filter to the front of the vehicle.
- Squeeze the connection for the EVAP hose near the filter and remove it.
- Disconnect the fuel pump electrical connection. When doing this, the connector may come out of the harness clip. If it doesn’t, remove the harness clip from the body.
- Position two jacks underneath the tank cover and lift them until they make contact with the cover.
- Loosen and remove the 13mm fuel tank strap bolt located at the rear on the passenger side.
- Loosen and remove the 13mm bolt at the front of the tank on the passenger side.
- Now, you can remove the 13mm bolt at the front of the tank on the driver's side. Hold the strap and then swing it down by hand.
- Lower the tank enough to expose the driver-side EVAP connections. Remove the hose with the clip first. (The clip on this one was missing.)
- Disconnect the rubber hose from the plastic hardline.
- On the passenger side near the filler neck, use a flathead screwdriver to remove the clip carefully. Disconnect the line.
- Disconnect the rubber hose from the plastic hardline.
- Begin lowering the tank a little more. Now you’ll want to remove the tank from the filler neck by pushing the tank to the driver's side of the car. If needed, spray some WD-40 around the filler neck grommet to help it slide easier. The grommet may get damaged.
- Make sure you move the tank enough so that the tip of the filler neck isn’t damaged.
- Once the neck is out of the tank, safely lower the tank to the ground.
- If you couldn’t get the fuel out of the tank, now would be the time to do so. We took the simple route and just dumped it into a storage container intended for fuel.
- Place the fuel tank on a workbench. Blow away the debris from around the fuel pump assembly.
- Disconnect the electrical connection from the pressure transducer.
- Loosen and remove the (6) bolts with an 8mm socket.
- Use a pry tool and gently lift the pump mounting flange away from the tank.
- Resituate any hose or component so that the two locking tabs on the module are accessible.
- Squeeze the two locking tabs simultaneously to remove the module from the tank by lifting up and out.
- To reinstall any components, reverse the removal steps. After that, you’re good to go.
Alright folks, like any of our how-to articles, we hope this has provided you with the information you need. Until we see you in the next one, y’all know what to do; for all things, SN95 and New Edge Mustang, keep it right here with the real Mustang enthusiast at LMR.com.
