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Stock 1991 - 1994 Explorers For questions related to the base Ford Explorer. Problem solving, maintenance, TSB, service bulletins, owner reviews, specifications. No modification questions.

Replaced sending unit, still no fuel gauge reading

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Old 01-07-2012, 02:12 PM   #1
'94 Limited
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Replaced sending unit, still no fuel gauge reading

The fuel gauge on my 94 Limited hasn't worked (properly*) for probably 7 or 8 years. Every time I get to 300 miles on a tank I'd refill.
Well I finally got around to the task of cutting a hole in the floor, pulling out the old sending unit, removing the original pump and placing it on a new sending unit with a new strainer, and placing that back in the tank. And replaced the fuel filter.
Turn it on and still no reading at the gauge... fffffuuuuuuuuuuuu-!!!
What do I check next?

*I mentioned it hasn't worked properly for 7 or 8 years. What I mean by that is the gauge would often show an initial full reading when I turned the Explorer on. But over the course of a couple miles the gauge would slowly but surely drop to empty and remain there for the duration.
This morning when I turned it on after replacing the sending unit it just stayed dead on the empty side. I threw my hands in the air and came in to take a multi-hour/beer long break.

Please advise and thanks in advance!
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Old 01-08-2012, 12:10 PM   #2
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So I started looking over the old sending unit that I removed and sure enough the brass float has a hole in it. A fair sized one right where it connects to the wire hanger.

This made me question the sending unit I just put in. So I popped the lock ring back off and shined a flash light in there. I've currently got a full tank of gas and the float is clear up at the top of it, floating.
Turned the key and still reads empty. Although the gauge did move around a little again. When I turned it on it was already above empty and it dropped down and then slightly lifted again.
In conclusion, I don't think my sending unit is bad and I don't think my gauge is necessarily bad.
The truck runs great and doesn't cut out or experience a loss in fuel at all.

Anyone have any ideas?
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Old 01-08-2012, 12:18 PM   #3
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Check the resitance at the fuel pump connector. If it reads good there, try checking the fuel gauge itself.

It may be just a bad connection in the plug-or a broken wire in the circuit.

This thread may help

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