Ford 8A4Z-9A299-CA
Fuel Gauge Sending Unit, Passenger Side

The fuel level service requires safety precautions to keep away smoking or carrying lighted tobacco products or open flame sources from fuel-related components because dangerous fuel mixtures exist. Users must prevent the use of personal electronic devices in areas surrounding fuel components. The procedure to work on fuel tubes and system components requires relieving fuel system pressure first to avoid accidents and professionals should always disconnect the battery ground cable during evaporative emission system or fuel-related component maintenance. A serviceable fuel level sender exists within the fuel level sensor device. The starting point should consist of releasing fuel system pressure followed by disconnection of the battery ground cable. Open the fuel pump module access cover while you inspect and clean all module connections with no debris present inside the surrounding area. Use absorbent towelling around the working area before disconnecting the fuel pump module electrical connector. Route the fuel tank jumper tube to a fuel storage tanker which should drain about one-fourth of the fuel until the sensor mounting flange becomes exposed in the lowered fuel level. Access the sensor cover of the fuel level and cleanse its connections before disconnecting its electrical wires. Cut the connections of the fuel vapor tube assembly and fuel vapor tube from the fuel level sensor. You should use the Fuel Tank Sender Unit Wrench to safety remove the fuel lock ring of the sensor unit while protecting the sensor from any damage. Use a suitable container to drain fuel from the tank while you remove the lock ring then extract the fuel level sensor by disconnecting the internal fuel tube coupling. Clean engine oil should be applied to a new O-ring before its installation and the old O-ring seal needs to be removed and discarded. Reverse the uninstallation steps by placing a new lock ring and O-ring seal then align the fuel level sensor arrows on the fuel tank before you tighten the lock ring to the stop tabs.

Clean the sensor connections and surrounding area, and disconnect the electrical connector. Place absorbent toweling nearby to catch any fuel spillage.