fuel gauge trouble

[punkbek3886]

i was just wondering if anyone else has had trouble in the past with their fuel gauges reading empty all of the time on the 91-94 model explorers. i think this might be a common problem for this model because i have a friend who has a ranger with the same chassis and his is reading wrong also.

 

[JWood]

Yep...I have the same problem on my 93

The gauge reads 1/4 tank with the key turned to "Off", and E when the key is on. I am told the problem is in the tank itself, the sending unit float or something like that. So, I just reset the trip odometer every time I gas up and fill it up each time.

Wasn't it FORD that used to say that "Quality goes in before the name goes on"....?

 

[dave93LTD]

Mine stopped working also. (150,000+ mi) Ater not driving it for a couple of weeks I went out one day and it was stuck on E. I tried driving it to empty the fuel tank and then filled it up but it hasn't moved.

Also, my voltage gauge is acting funny. When I start the engine it is pegged in the upper left corner and I have to thump the plastic to correct it.
Is it difficult to change the gauges? Are there any aftermarket kits to help with this swap?

 

[punkbek3886]

i imagine that it probably isnt the gauges but the sensors that should be sending the correct voltage to the gauge. there's a test that you can do to see if the sender unit is working. ill try that and tell you guys if thats what it is.

 

[410Fortune]

Okay two things:

Yes the fuel gage problem is VERY common among any Ford vehicle with the in tank sending unit/float

If you are having problems with more then one gage then it could be the IVR instrument voltage regulator. This little doodad is behind your instrument cluster, it looks kinds like a 9v battery, Ford dealer sells them cheap, and you can replace it yourself if you have the ability to remove your dash trim pieces and gage cluster.

the fix for the faulty fuel gage is most likely a new in tank sending unit, requires dropping the gas tank. The fuel pump and sending unit are one piece and are replaced together when the tank is dropped. Also before going through this trouble you can check the wiring harness for a loose/dirty connection at the fuel tank. It is a PITA to get to and see, it is located on top of your gas tank, but it is a lot easier to check then just dropping the tank.

It is common for the actual sending unit float to get a hole in it, fill up with gas, and sit on the bottom of the tank, causing the gage to read empty at all times.......
Oh and be careful, aftermarket fuel pumps and gage sending units dont always read correctly and may require adjustment, which means dropping the tank again.....I didnt adjust mine and now my gage reads full when full, 1/2 tank when 3/4 full , and empty when I still have 8 gallons................

 

[410Fortune]

Originally posted by 410Fortune
Okay two things:

Yes the fuel gage problem is VERY common among any Ford vehicle with the in tank sending unit/float

If you are having problems with more then one gage then it could be the IVR instrument voltage regulator. This little doodad is behind your instrument cluster, it looks kinds like a 9v battery, Ford dealer sells them cheap, and you can replace it yourself if you have the ability to remove your dash trim pieces and gage cluster.

the fix for the faulty fuel gage is most likely a new in tank sending unit, requires dropping the gas tank. The fuel pump and sending unit are one piece and are replaced together when the tank is dropped. Also before going through this trouble you can check the wiring harness for a loose/dirty connection at the fuel tank. It is a PITA to get to and see, it is located on top of your gas tank, but it is a lot easier to check then just dropping the tank.

It is common for the actual sending unit float to get a hole in it, fill up with gas, and sit on the bottom of the tank, causing the gage to read empty at all times.......
Oh and be careful, aftermarket fuel pumps and gage sending units dont always read correctly and may require adjustment, which means dropping the tank again.....I didnt adjust mine and now my gage reads full when full, 1/2 tank when 3/4 full , and empty when I still have 8 gallons................I have also been told that you can wire in a resistor from radio shack to help "adjust" your fuel gage without dropping the tank, I never tried so I dont know if this works or not. On my BII I can drop the gas tank in about 30 minutes, so someday when I have time I will attempt to adjust the float myself....

Special precautions must be taken when working on a fuel tank so be aware of these before you dive into dropping your fuel tank. Obviously it is easier to drop and lift a empty tank then it is a full one, you need to cover up any holes with duct tape while the tank is out to stop dirt/whatever from getting in and to help eliminate fumes from escaping. Also do not use any tools that may create a spark (BOOOM!!!!) so a rubber mallet and wooden dowl are perfect for removing and installing the intank pump unit (It spins in and out, kinda like a gas cap on a dirt bike)

 

[S.Matsushige]

Its the sensor. I'm on my second one in my Explorer. Not the easiest part to change since you'll have to drop the tank to replace it. Run the tank as empty as possible and use a floor jack if you have one. Makes it a whole lot easier when trying to get the tank back up. Funny thing is they sell the fuel pump assembly minus the sensor, yet you have to purchase the entire pump for the sensor. Good luck!

 

[410Fortune]

Well even if you can replace just the gauge sensor, if you are going to go through the trouble of dropping the fuel tank it's a good idea to replace the pump for the "higher" mileage guys......

Kinda like if you're gonna have the tranny down you mine as well install a new clutch, and if you have te hubs you mine as well service them, and if you have the rotors off you mine as well pack the bearings......etc

I would not "skimp" on the quality of the replacement fuel pump, dont want that sucker going out on you....

 

[S.Matsushige]

Good point - 410fortune is right. Get a good quality one and don't skimp. After having to do it a couple of times, you'll wish the sensor would last forever.

 

[93Sport]

My '93 Sport's fuel gauge was always indicating empty about a year ago. Replaced the gauge and it worked fine for about 9 months (gauge with pretty expensive from Ford). After 9 months, it always reads full. This time, it wasn't the gauge, pump, sender, or float. It was actually a section of the wires pin to the chassis and was grounded. The mechanic rewired that area and it works fine now (lets pray that's the last of my fuel gauge problems).

 

[explorer4x493]

Re: Yep...I have the same problem on my 93

Originally posted by JWood
The gauge reads 1/4 tank with the key turned to "Off", and E when the key is on. I am told the problem is in the tank itself, the sending unit float or something like that. So, I just reset the trip odometer every time I gas up and fill it up each time.

Wasn't it FORD that used to say that "Quality goes in before the name goes on"....?

Wait a min....are you dissin Ford???

 

[JWood]

Nah...It's just a little frustration...

after spending time and money keeping my '93 running. So, call me crazy.... but I have purchased 2 more new Fords this year - An F150 XLT and an Explorer XLS.