Fuel Gauge - Intermittently Drops to Empty

Article No.
03-6-5

03/31/03

ELECTRICAL - FUEL GAUGE INTERMITTENT DROPS
TO EMPTY - SENDER KIT AVAILABLE FOR
SERVICE - VEHICLES PRODUCED BEFORE 5/20/2002
EQUIPPED WITH 4.0L ENGINE ONLY

FORD:
2002 EXPLORER

MERCURY:
2002 MOUNTAINEER

Article 03-1-8 is being republished in its entirety to clarify vehicle model and line coverage and to specify unaffected vehicles.

ISSUE
Some 2002 4dr Explorer/Mountaineer vehicles equipped with a 4.0L SOHC engine and 5R55W/5R555 transmission, may exhibit an intermittent fuel gauge level dropping to empty when fuel level is not actually empty. Diagnostic Trouble Codes (DTC's) B1201, B1202, B1204, may or may not be present. This may be due to an intermittent open circuit within the in-line Flex Fuel Module (black oval device with the fuel pump wiring pigtail) known as an AC/DC convertor.

ACTION
Install a Flex Fuel Module Wiring Pigtail Kit 2L2Z-9B357-AA. Refer to the instructions included in the kit.

IMPORTANT:
Canadian built 4.0L 4dr Explorer/Mountaineer vehicles built before 3/4/2002, 4dr Explorer/Mountaineer with manual transmissions or 4dr Explorer/Mountaineer vehicles equipped with 4.6L V8 powertrains are not equipped with AC/DC converters.

NOTE:
If vehicle contains any of the above criteria under the heading IMPORTANT, continue with normal vehicle diagnosis.

SERVICE PROCEDURE

IMPORTANT:
Vehicles that do not contain an AC/DC converter are not effected by this article.

Continue with normal Workshop Manual diagnosis.

Unaffected Vehicles

^ Canadian built 4.0L 4dr Explorer/Mountaineer vehicles built before 3/4/2002

^ Manual Transmission Equipped Explorer/Mountaineer vehicles

^ 4.6L V8 Equipped Explorer/Mountaineer vehicles

^ Applicable vehicles built 5/20/2002 and later us a different fuel pump/connector. Kit 2L2Z-9B357-M cannot be used.





Labor Operation Claiming Chart





Parts Block

OTHER APPLICABLE ARTICLES: NONE

SUPERSEDES: 03-1-8

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

DEALER CODING
CONDITION
BASIC PART NO. CODE
9H307 42

OASIS CODES: 203000, 203200, 204000, 204200





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