Instruments - Fuel Gauge Reads Between 3/4 and 7/8 Full
TSB 08-19-109/29/08
LONG WHEEL BASE (LWB) - FUEL GAUGE READS
BETWEEN 3/4 AND 7/8 WHEN FULL
FORD:
2007-2008 Expedition
LINCOLN:
2007-2008 Navigator
ISSUE
Some 2007-2008 Expedition and Navigator LWB vehicles may exhibit a refueling issue where the customer states they refuel the fuel tank and the gauge reads between 3/4 and 7/8 full.
ACTION
Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Question the customer - yes/no.
a. Refueling event more than a 5 gallon fill?
b. Customer refilled with the engine off?
c. Customer refilled to 1 to 3 auto-shutoffs?
NOTE
SOME CREDIT CARDS HAVE PRESET LIMITS ON THE DOLLAR AMOUNT AVAILABLE FUEL TRANSACTION. THE PUMP WILL SHUT OFF AT THIS LIMIT. THIS LIMIT MAY BE IN THE RANGE OF $50 TO $75.
If the answer is No to any question, this procedure does not apply. This is the normal system function. The system may not recognize less than a 5 gallon fill or filling up with the engine on and it will be slow to update the gage to the correct fill level. Also, the first auto-shutoff is designed to read full.
2. Follow Workshop Manual (WSM), Section 413-0 Pinpoint Test A: Instrument Cluster, Message Center, and Warning Chimes to determine if the cluster is capable of reading the 4 fuel levels, using IDS active commands.
a. If not okay, refer to WSM recommendations.
b. If okay, go to Step 3.
3. Follow Pinpoint Test A Section 413-01:
Instrument Cluster, Message Center, and Warning Chimes to determine if the cluster can read 4 fuel levels using the gage tester.
a. If not, refer to WSM recommendations.
b. If okay, go to Step 4.
4. If the vehicle was built prior to 7/1/2008, remove and inspect the fuel pump. Verify sender float rod clearance to convolute fuel supply hose by sweeping the float to the full position. Is the clearance more than 3/16" (5 mm) between the fuel soaked hose and the rod?
a. If clearance is equal to or greater than specified, go to Step 6.
b. If clearance is less than specified, go to Step 5.
5. Follow Pinpoint Test A Section 413-01:
Instrument Cluster, Message Center, and Warning Chimes to determine if the sender card meets the 10 to 180 ohms specification?
a. If within specification, follow WSM recommendation.
b. If not within specification, go to Step 6.
6. Replace the fuel delivery module (FDM) with certified stock. Check for a blue pen marking near the gray fuel supply port on the sender flange.
a. If blue pen mark is present, use the FDM as the replacement.
b. If blue pen mark is not present on the FDM flange, please verify the sender float rod clearance to convolute fuel supply hose by sweeping the float to the full position. If the clearance between the float rod and the convolute fuel supply hose is less than 13/16" (20 mm) on a dry hose, do not use. Order a new FDM and repeat inspection for blue markings and/or clearance before replacing.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.
OPERATION DESCRIPTION TIME
MT081901 Use SLIS Operations If Actual
Available; Claim Additional Time
Diagnosis Or Labor
Performed As Actual Time.
DEALER CODING
CONDITION
BASIC PART NO. CODE
9H307 42
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