Fuel Gauge - Inaccurate Reading When Tank is Full

Article No.
96-4-5

02-12-96

GAUGE - FUEL - INACCURATE FUEL LEVEL READING WHEN TANK IS FULL - VEHICLES BUILT FROM 9/1/94

FORD:
1995-96 PROBE

ISSUE:
The fuel gauge level may read 3/4 full when tank is full on some vehicles. This may be caused by a bent fuel pump return tube improperly positioning the fuel tank float, and sending a less than accurate reading to the fuel level gauge.

ACTION:
Replace the fuel pump if distance from centerline of fuel sender-to-fuel pump flange is not within specification. Refer to the following Service Procedure for details.

SERVICE PROCEDURE

1. Verify the concern.





2. Check the resistance at Pins 1 and 2 of the fuel sending unit connector (Figure 1).

^ If the resistance is higher than 4.0 ohms when the tank level is full, then the fuel pump return tube is bent.

^ It the resistance is less than or equal to 4.0 ohms, refer to the appropriate year Probe Service Manual, Section 13-01, for further diagnosis.

3. Drain and remove the fuel tank per appropriate year Probe Service Manual, Section 10-01.

4. Remove fuel pump/sender from fuel tank.





5. Measure the distance from the centerline of the fuel sender to the fuel pump flange. The distance should be 59.6 +/- 1.5 mm (2.35 +/- 0.06") (Figure 2).





6. If measurement is out-of-specification, replace fuel pump (refer to the Fuel Pump Application Chart in this article).

7. Reinstall fuel pump/sender into fuel tank.

8. Reinstall the fuel tank per the appropriate year Probe Service Manual, Section 10-01.

9. Verify the repair.

PART NUMBER PART NAME

F32Z-9A407-A Fuel Pump
F52Z-9350-AA Fuel Pump
F42Z-9275-A Fuel Sender

OTHER APPLICABLE ARTICLES: NONE

WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage

OPERATION DESCRIPTION TIME

960405A Replace Fuel Pump 1.1 Hr.

DEALER CODING
CONDITION
BASIC PART NO. CODE
9350 79

OASIS CODES: 204200, 206000