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How to Replace DEF Sending Unit 11-16 Ford F250 Diesel

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How to Replace DEF Sending Unit 11-16 Ford F250 Diesel

Created on: 2017-04-19

How to repair, install, fix, change or replace a broken, damaged, worn out, faulty or shorted out diesel exhaust fluid or DEF sending unit on 13 Ford F250 pickup truck.

  1. step 1 :Removing the Skid Plate
    • Remove the 13mm bolt at the front part of the skid plate on the drive side of the driveshaft
    • Remove the two 13mm bolts on the back strap
    • Remove the five 13mm fasteners on the frame rail side
    • Lower the skid plate down and out
  2. step 2 :Loosening the Filler Neck
    • Open the fuel door
    • Remove the three 5.5mm screws
    • Remove the cap on the DEF filler neck
    • Pull the filler neck down and out
    • Replace the cap
  3. step 3 :Removing the DEF Tank
    • Disconnect the grayish-white connector on top of the tank
    • Pop the other end of the connector out of its bracket
    • Pry out the two DEF injector hose retainers
    • Remove the 13mm bolt on the DEF tank bracket
    • Remove the 13mm bolt on the backside of the DEF tank
    • Slowly lower the DEF tank out of the vehicle
    • Send the filler neck over the frame
    • Disconnect the injector line connector
    • Compress the pins on the injector and wiggle the line off
    • Slide the DEF tank out
  4. step 4 :Removing the Sending Unit
    • Disconnect all the electrical connectors on the sending unit
    • Remove the three 4mm Allen bolts securing the module to the top of the tank
    • Remove the module
  5. step 5 :Installing the Sending Unit
    • Reinstall the module
    • Tighten the three 4mm Allen bolts
    • Connect the wiring harnesses
  6. step 6 :Installing the DEF Tank
    • Slide the DEF tank underneath the frame
    • Send the filler neck and lines over the frame
    • Reconnect the injector nozzle
    • Connect the injector connector harness
    • Lift the DEF tank up
    • Tighten the four 13mm bolts to the tank
    • Reconnect the main electrical connector
  7. step 7 :Installing the Filler Neck
    • Remove the DEF cap
    • Reinstall the filler neck into the fuel door
    • Reinstall the three 5.5mm screws
    • Reinstall the collar over the threads
    • Reinstall the DEF cap
  8. step 8 :Reinstalling the Skid Plate
    • Lift the skid plate up into place
    • Set some nuts in to keep the plate level
    • Tighten the 13mm hardware

Tools needed for replacement

  • General Tools

    Flashlight

    Pick

  • Hex Wrenches

    4mm Hex Wrench

  • Materials, Fluids, and Supplies

    Gloves

    Safety Glasses

  • Ratchets & Related

    Socket Extensions

    Ratchet

  • Sockets - Metric

    15mm Socket

    5.5mm Socket

Installation Video
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Hi, I'm Mike from 1AAuto. We've been selling auto parts for over 30 years! We're dedicated to delivering quality auto parts, expert customer service, and fast and free shipping, all backed by our 100% satisfaction guarantee. So visit us at 1AAuto.com, your trusted source for quality auto parts.

In this video, we're going to be working with our 2013 Ford F-250 Super Duty with the 6.7L Power Stroke Diesel. We're going to be showing you how to remove and replace your vehicle's DEF, or reductant sending unit, for the diesel exhaust fluid tank.

If you like this video, please click subscribe. We have a ton more information on this and many other vehicles, and if you need parts for your truck, you can follow the link down in the description over to 1AAuto.com.

Here are the items you'll need for this repair: 5.5 to 15mm socket, ratchet, socket extensions, 4mm Allen wrench, pick tool, safety goggles, gloves, flashlight

Remove the 13 millimeter bolt at the front part of the skid plate at the center of the truck. This is just to the driver's side of the driveshaft. Remove that with a socket ratchet and some extensions. Then remove the two 13 millimeter bolts on the back strap. This is at the rear of the truck about two feet ahead of the rear differential depending on your wheel base.

Remove the five fasteners on the frame rail side. This is on the driver's side of the skid plate. There are two bolts here at the front, a nut just about flush with the rear cab mount, another bolt tucked up in here just after the leaf spring perch, and all the way at the back closest to the axle, there's another nut. We'll remove all of these with 13 millimeter socket and ratchet as well as various extensions as necessary. Now I'm supporting the skid plate with my knee as I remove the last bolt. These little metal clips can be meddlesome. Then lower the skid plate and slide it out of the way.

Open the fuel door and remove the three 5 1/2 millimeter screws, securing the DEF filler neck with a socket and ratchet. Remove the cap on your DEF filler neck. Along with the little safety collar on it here that just pops off the threads. Pull the filler neck down and through. And we'll screw the cap back on just to prevent any spills or other issues while we're working on it.

On top of the DEF tank are all these connectors. This large grayish-whitish connector here toward the back just above the brake lines and the ABS sensor bracket is connected to all of them. So we'll disconnect that and use a trim tool to pry it off of the bracket so we don't have to disconnect everything individually. Once the connector's disconnected, pop the other end of the connector off of its bracket. We'll also use a trim tool to pop off the connectors or the retainers for the DEF injector hose so we have enough room to drop our DEF tank down and then disconnect the injector hose as opposed to trying to do it blind where we are now. We'll then remove this 13 millimeter bolt on the DEF tank bracket under the center of the truck. We'll then remove the two 13 millimeter bolts on the backside of the DEF tank. These are just above the head of the axle. I'm using my forearm and chest to support it so we can lower it down and out in a controlled fashion to remove the last bolt. Once the last bolt's out, carefully lower your DEF tank.

I'm now going to remove myself out from under it. Be careful of your filler lines coming over top the frame as well. Send your filler neck over the frame. Undo this connector on the injector line and then pinch. You kind of want to push in and then there's this tab here and its twin on the other side. You'll want to compress both of those with your hands. And then just wiggle that injection line off. Let that hang out of the way. We'll slide our DEF tank out from under the truck.

Disconnect the electrical connectors on the sending unit. This one's a little tricky, so you may want to use a hooked pick and just kind of pop up the tab. Remove that. Disconnect all the other ones while we're here. Now it may not be entirely necessary to remove all of these connectors. We just want to make sure that we have plenty of slack when we remove our harness. Once everything is unplugged, remove the three four-millimeter Allen bolts, securing the module to the top of the tank. Remove the module from the top of the tank.

Install the module back on top, and reinstall the three 4 mm Allen screws. Reconnect the harness. Remember, these two get plugged in once this goes back into the vehicle.

Slide your DEF tank back under the vehicle. Carefully send the filler neck and lines over the frame. Be careful not to twist them up and let them get kinked. Reconnect the injector nozzle and connector.

Reinstall your DEF tank into the truck. Reinstall all of the 13-millimeter bolts in your DEF tank. We'll now tighten down all of this hardware with our 13-millimeter sockets, ratchets, and extensions. Reconnect the main electrical connector on your DEF tank. Remove the DEF cap and reinstall the filler neck into its spot behind the fuel door. We'll then reinstall the three 5 1/2 millimeter screws with the socket and ratchet. Reinstall the collar over the threads and screw in your DEF cap.

Install your skid plate. I'm using my knee to hold it up in place while I set the two 13-millimeter nuts as those are the fastest piece of hardware to install. Once that's in, I'm going to slide under it and install bolts on the other side to keep it level and in place. You can now tighten down all the 13-millimeter hardware with the socket, ratchet, and extension.

Thanks for watching. Visit us at 1AAuto.com for quality auto parts, fast and free shipping, and the best customer service in the industry.

Tools needed for replacement:

    General Tools

  • Flashlight
  • Pick

  • Hex Wrenches

  • 4mm Hex Wrench

  • Materials, Fluids, and Supplies

  • Gloves
  • Safety Glasses

  • Ratchets & Related

  • Socket Extensions
  • Ratchet

  • Sockets - Metric

  • 15mm Socket
  • 5.5mm Socket


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