Replacing the Front Gas Tank on a '96 Ford F150

[@haydenfoutz8634]

This video is awesome!! I've looked all over to find a video that doesn't fast forward through all the important parts and there's usually some really obnoxious music playing during the fast forwarding. I have just loved everything about this video. Good quality and great tools.

[@BusHuxley]

Thank you very much. This is exactly what I was hopping to accomplish with this video. Thank you for recognizing this fact. Your complaints with DIY videos are similar to mine, so i try to make what I would need. I could have done more on this one as far as explaining tools and noting the sizing. Next time.

[@pixelvault2807]

I used to have a Chevy that loved to kill fuel pumps. Helpful tip for viewers. Use your hydraulic jack to lift and lower your gas tank into position. Still a miserable job, but a little less miserable.

[@BusHuxley]

This is a very good tip. A ratchet strap could have been of use as well.

[@mongomay1]

Thanks for sharing and the tape tip, thought of using 30# roofing felt in a couple of wraps.

[@airlandsea]

That was a great video, and very encouraging. I had the rear one replaced not too long ago and my mechanic said it would be about another $800 to do the front one too. Unless that tank is very expensive, I can't see how the labor would be that bad. Unless I missed something. Now I'm thinking of doing it myself. Thanks

[@BusHuxley]

Yes, it’s really not that bad a job to do yourself if you’ve got some tools and a little time.

[@airlandsea]

@@BusHuxley I have both! What about the disconnects? I think you need a special tool for those? Mind telling me where you got the tank? Thanks.

[@BusHuxley]

@@airlandsea I think I linked it in the description. It was a special tool from Napa to pull the connector at the tank. Five bucks I think. Tank was very cheap. 80? But that was six or seven years ago.

[@chiefjaspil]

You made that look pretty easy; good video and sound; speed up video at times perfect our time is valuable too. Prep note about releasing pressure on tank lines and adding in a fuel filter replacement would be good added features. You should do more when performing your repairs on this vehicle they would be viewed I am sure. Thank You very much Mr Huxley, Dog nice added attraction. You make me want to film mine but I do not have the camera what ever it takes to do it.

[@BusHuxley]

Thanks a lot! I really appreciate this comment. Unfortunately that truck is now toast. The engine and transmission are still fine but the frame is broken. Rust never sleeps i hear. Thank you sir.

[@chiefjaspil]

Nice touch having all those associated parts listed, thanks for sharing

[@BusHuxley]

Thanks a lot!

[@fredkeller3813]

Very good video, thank you! Short and to the point. I hope the replacement of my tank only takes 5 minutes and 28 seconds. PS that's a good looking girl you had sitting in the truck next to you!

[@darrylmcleman6456]

Yes, but I thought she was a bit of a dog!!!

[@flyifri]

I like to chip guard my tank before installing. Extra goes on the top. Works great.

[@BusHuxley]

Thank you. I wish i had done that. Is it like a rhino liner?

[@ShowPeaceEnt]

mr Huxley... it was the terminal. lol. thank you very very much sir. shes alive.

[@terrybaptist795]

You did a great job on replacing your front gas tank.

[@BusHuxley]

Thanks

[@hugocadena116]

Thanks for your video, this is will help me putting my gas tank on my truck.

[@BusHuxley]

Im glad!

[@jimbezich2196]

Do you have a wiring diagram , my new tank and pump has 4 wires of a different color than the original ford 1996 f150 5.8 the new pump harness has purple, black-white stripe, grey, black. Just need the truck harness side to match up to the correct wires on the pump harness

[@Lenny4400]

Hello l have "two" gas ⛽ tanks .lf one fuel pump goes out can the second tank be used?

[@rll1954]

The nuts for the strap bolts are 15mm on my '93.

[@sknerl]

13mm over top 15mm bottom on mine.

[@snowman374th]

Was this leak by chance making your engine sputter and then back fire if you drop the throttle? I have a leak where you pointed to. And it seems to be a hose. But Im taking the tank down to see better.

[@ShowPeaceEnt]

lol terminal. last night i did notice acid dust stuff on the battery. I'll give that a shot. thanks man. i appreciate you

[@BusHuxley]

Well thanks a lot! Any luck with the terminals?

[@claytonrobinson3274]

My rear tank is running in the tank. How Can I stop that.

[@jb79546]

Great video!

[@BusHuxley]

Thanks a lot!

[@LolitasGarden]

I recently purchased this repair (and others!) on a manual '90 F150. Wish me luck.

[@BusHuxley]

Heck yeah! A wildly robust machine to be sure. Reach out via email with any questions. I hope to see you up this way fore too long;

[@shdwbnndbyyt]

Having done this previously on a Chevy Silverado from underneath (and getting a piece oif rust in my eye requiring an emergency room visit -- despite safety glasses), I plan on removing my 96 F-150 truck bed first this time. I also have painted my new front tank with multiple layers of paint (leaving grounding spot), as I hope to never have to do this again.... Note that my front tank's pump appears to have died based on my troublshooting, the rear tank has finally been shown to be leaking (pin hole) -- Of course from what I have read, the F-150 sends all of the unused gas to the front tank via the return line, so there is overflow leakage there....

[@BusHuxley]

Just such a nightmare. That horrible;e rust. I just had to scrap this rig. The frame finally gave way and looked like the old tank. Such a shame. Maine! Rust all the time.

[@shelbyupshaw7760]

I really like your video. I only have my front tank running my truck for now, I need to know what's making the tank overflow?. Can you help me ?

[@BusHuxley]

I had the same problem after I installed a new fuel pump. The little clips that hold the fuel line in into the pump need to be tight. Also, the wedge type gasket which seals the fuel pump into the tank also needs to be tight. And there may be a crack in the fuel filler neck. Good luck. It should be one of those three. Or, obviously a hole from a rusty tank. Thats what I had going on.

[@dancingwithczars]

Some Ford F-150 dual-tank pickups from 1990-96 have cross-flow problems caused by a defective shuttle valve on the return line side of the fuel pump assembly. I have a '96 F150 with dual tanks. When I run on my rear tank the return flows mostly into the front tank causing it to fill up while the rear tank rapidly empties. That's because the shuttle valve on the front tank is bad. If I fill up both tanks and run off the rear tank first, it will cause the front tank to overflow. So I have to run the front tank first. The remedy is to replace the front fuel pump assembly. Ford has largely covered up the problem because the trucks are old, but many are still on the road and are a safety hazard when gas comes pouring out of an overflowing tank.

[@josephcalabrese6337]

I got two questions. 1: Is the 1996 Ford F150 long bed similar to the 1994 Ford Ranger XLT? (I have a 94.) 2: About the gas tank you used. Can I use that very model tank to replace my old-leaking tank? I want to buy a new tank online, But I have failed to see anybody selling the exact same shape of tank under my truck.

[@BusHuxley]

Thanks for the questions. Unfortunately, I don't think i can be a whole lot of help to either of them, as I have never wrenched on a ranger. My feeling is that they are different tanks, judging from a quick google search and the size of the bed is so much different. But they may be the same. I have a feeling the way you would change them would be pretty similar. Good luck.

[@UrbanFlow3825]

Try rockauto.com if you haven't yet they have a lot of parts that are hard to find for the f-150

[@Spennyman10]

I almost laughed out loud at 2 am over the "Rusty" comment. Thanks for the vid.

[@BusHuxley]

Yes!

[@mybreathyourlung]

I’m hoping that was a Seinfeld reference!

[@gabrielortiz665]

Coool vid

[@jimbezich2196]

To answer my own ? the harness from 1aauto fuel tank and pump was a match nothing needed but to push it together

[@robertbarrett9921]

Cool video

[@BusHuxley]

Robert Barrett Thanks. I hope it helped.

[@sinisterspawn]

When swapping tanks do we need to replace the Fuel reservoir switch as Well? It's the switch that allows you to switch between both tanks

[@BusHuxley]

FILTHY OAX Nope. In my case the back tank had never worked since I owned it, but the switch should be fine.

[@sinisterspawn]

Bus Huxley cool thanks Man!

[@ShowPeaceEnt]

lol it works!... I enjoyed your video... question, I just installed my tank on my f150, everything is connected, however truck wont turn on. I will go and put more gas in it, but the engine won't even turn. as soon as i turn the ignition, the battery cuts off. I would then have to move the battery terminal to get the power back on. dont know what to do. any advise?

[@BusHuxley]

Thanks a lot! It sounds like you may have dirty connections at the terminals or a short somewhere in the system. Clean the terminals really well with a terminal cleaner or wire brush. If that doesn't work it may be grounding out down by the fuel pump. Probably just the terminals though. If there are any cracks in the terminal cables that could cause problems too. I'll write terminal one more time.

[@Leorodas545]

Thank you for the video, very helpful. Hey man what are the specs on the tank you installed? I found a few different ones on amazon but I don't want to buy one that wont fit. Do you have a link by chance?

[@BusHuxley]

Hey there! Thanks a lot for the comment. In fact I meant to post a link to this amazon page when i did the video two years ago! Because I ordered the wrong one the first time, which, as you can imagine, was enraging! ill post it here and in the description. www.amazon.com/gp/product/B000C7TWA0/ref=oh_aui_detailpage_o09_s00?ie=UTF8&psc=1 Its a pretty easy job, all in all. The fuel line tool you can get at napa for ten bucks

[@Leorodas545]

Bus Huxley. Wow thank you so much. When I bought my truck it was already missing the front tank. It had been removed. The pump and hardware you used is from your old tank? Thank you so much for that link

[@automotivehulk5817]

Love it

[@BusHuxley]

Thanks!

[@Redneckf350]

Can I have that slab of wood that the new tank was up against?!! Looked like a nice 10/4 slab with a sweet live edge. What kinda wood?

[@BusHuxley]

Hey there! You cannot have it but you can buy it! I'm kinda kidding. Its a massive slab of pine that I ripped with a chainsaw to make a table, and have a four part video series of me doing just that on my channel! You should check it out. The fifth video is nearly done. Its a beast. Thanks for the comment!

[@lynnyarbroughplyler7447]

can I cut off the rear tank and bypass it so I use only the front tank?

[@BusHuxley]

Lynn Yarbrough Yes you can. That's exactly what I did. In fact all you have to do is not turn on the switch to the rear tank ever. Thanks for the question.

[@kd5dvmkatdaddie114]

Thank you.

[@BusHuxley]

kd5dvm Kat Daddie My pleasure. Glad it could help.

[@catherinewelch4824]

we replaced this same one in mine and it stalls out at an 1/8 of a tank, why is that

[@BusHuxley]

Hey there. Thanks for checking out the video. If I had to guess, I would say that the fuel pump has a slight angle to it and doesn't quite fit the new tank perfectly, and running dry sooner than it should. I had a similar issue with this old beast and now I just maintain a fuller tank. But, this may not be it at all. As you can see, I am no expert! I hope this helps.

[@catherinewelch4824]

Thanks

[@jordanclay5688]

Catherine Welch it's mostly your shower head, my 92 7.3 is having the same issue, it's cuts off on me with a quarter of a tank left

[@georgelefebvre7982]

@@BusHuxley Many aftermarket tanks do not come with a baffle. The baffle is what mitigates the affect of fuel slosh to prevent a stall condition when cornering or changing directions, It could be that as well. Good work Bus! Just found your channel a while back. I'm addicted!

[@lamontgray6015]

Why do they have two tanks do you need em both?

[@BusHuxley]

I guess it was just to extend the range. One does not need two to run the rig. My rear one has never worked since i owned the truck. Ive had them where they both worked and it was a serious payment to fill up, but was nice knowing i didn't need to stop again for a while.

[@lamontgray6015]

Bus Huxley how long chuld you drive on two,full tanks and chuld you just fill up one when both are working

[@daminor1986]

So no fuel filter for the front tank?

[@BusHuxley]

I think there was an inline one

[@dylangrubbs0]

I'm having problems disconnecting the fuel lines to drop the tank.

[@BusHuxley]

There is a special tool to get at napa for ten bucks, They'll know what you need

[@jeremyrollins4074]

​@@BusHuxley I have a 16 gallon tank in my singke cab long bed 8ft with the dana 60 an dana 70 I already changed the rear tank 19 gallon was tht a 19 gallon u put into ur truck an was ur truck a a single cab long bed I've heard I can swap a 19 gallon in my truck but then I've heard ita only in Cree cabs or short bed trucks or diseal plastic tanks Mines a 97 f350 long bed single cab obs

[@happyman7686]

He doesn't explain what he is taking off. This video is made for his buddies that already do this type of work. We're not mind reader.

[@BusHuxley]

Thanks for the feedback.

[@natanator3956]

Does a guy need that special tool for the fuel lines?

[@BusHuxley]

Yes. Very cheap.

[@rickstolfa149]

What is the difference between the front (19 gal) and rear tank (18 gal). I'm having difficulty finding parts on line.

[@BusHuxley]

The way they fit is quite different. They are certainly not interchangeable. I found mine on Amazon, spectra was the make. It fit quite well. Make sure you get new straps too. And while your in there you should change the fuel pump gaskets and all that. Thanks for the question.

[@thomasriley6263]

Back is a square front is a rectangle

[@thomasriley6263]

Simplest way I can explain it

[@terrybaptist795]

Which engine and transmission does your 1996 F150 have?

[@BusHuxley]

Terry Baptist 4.9 straight six and the 5 speed.

[@sdmcx2]

Thanks

[@BusHuxley]

My pleasure.

[@madisonmorton9989]

can you tell me how many portals this tank has, thanks

[@BusHuxley]

I think it was two and two gas lines in

[@madisonmorton9989]

@@BusHuxley thank you, I have a 1996 ford f150 5.0 with both front and rear tanks rotted and leaking. Trying to find out how many gallons each tank holds and the amount of tube ports they have has been an adventure, thanks, Madison

[@regimenservas9233]

"Thanks strange tool that cost me $5" Lol. Those fuel line detachment clamps?

[@BusHuxley]

Thats right. So specific!

[@BLueFeaTHeRedOliVeS]

Where'd you get the new strap(s)?

[@BusHuxley]

BLUEFEATHEREDOLIVES I think they came with the tank

[@BLueFeaTHeRedOliVeS]

@@BusHuxley thank you for the reply! Noted

[@MichaelKirbyMusic86]

This is what I'm getting ready to do, replace tank, strap, pump, & filter in my 96 f150 xlt 4.9. Going to do away with my rusted out rear tank for now due to limited funding & just run the front tank.

[@BusHuxley]

Thats what i did.

[@davehogan8205]

how long did this job take?

[@BusHuxley]

Few hours?

[@thomasgomez6755]

man and his dog.

[@BusHuxley]

Yeah. He was such a good natured guy. He loved to ride in that truck.

[@sinistar372]

My kingdom for a hydraulic lift.

[@BusHuxley]

+Laurentide That's right! My eight inch beams ripped into ramps are better than nothing, but the whole time I kept thinking about the joy it must be to stand and work. Neck pain? Corn flakes or rust in the eye? A thing of the past.

[@sinistar372]

+Bus Huxley If you have a place to put it they're not *that* expensive, but you have to do a lot of this stuff to make it worthwhile. Jackstands scare me but they do their thing.

[@micxploed]

I thought your passenger was a woman. Lol

[@BusHuxley]

Ha! He is a pretty cute dog! Thanks for the comment.

[@mudroost8040]

Banging on the fuel pump retaining ring with metallic tools could be hazardous to your health.... Just sayin'.

[@BusHuxley]

Mud Roost Thanks for the heads up.