Fuel Gauge - Diagnostic Procedure/Service Tips

Article No. 86-21-7

GAUGE - FUEL - DIAGNOSTIC PROCEDURE/SERVICE TIPS

FORD 1986 TAURUS

LINCOLN-MERCURY 1986 SABLE

The following information is being published to assist the technician in servicing magnetic fuel gauge concerns on Taurus/Sable vehicles. This information does not supersede the Shop Manual and should be used as a general guide.
Fuel and Temperature Gauge will not function:

^ Check instrument cluster fuse. Replace if blown.

^ Inspect power terminal at instrument cluster "flex" connector. If poor, modify for good electrical contact.

^ Inspect terminal clips at back of gauge for electrical contact. If defective, correct problem.

^ Broken power wire at gauge, replace the gauge.

^ Bad solder joint on gauge terminal, replace gauge.

^ Instrument cluster connector is not seated.
Fuel Gauge Pointer does not drop below full:

^ Check for opens in sender wiring, correct problem.

^ Inspect fuel sender resistor card for opens. If defective, replace sender.

^ Inspect the cluster electrical connector for contact to the flex circuit.

^ Observe the gauge to electrical clip interface for opens.

^ Check internal connection of gauge for an open. If open, replace gauge.

Pointer stays on full too long:

^ Check gauge for out-of-calibration. Connect 22.4 ohms to sender terminal and gauge should read empty. Connect 145 ohms to sender and the gauge should read full. If not, replace fuel gauge.

^ Inspect sender for calibration. If defective, replace.

^ Inspect sender for opens in the resistor card. If defective, replace.

^ Check to see that an 18 gallon sender is not in a 16 gallon tank.

Pointer will not go below 3/4:

^ Pointer staff is broken. Replace gauge.

^ Internal magnet in gauge is cracked. Replace gauge.

^ Applique is lifting off of dial, causing the pointer to bind. Replace gauge and dial assembly.

^ Check calibration of gauge. If incorrect, replace gauge.

OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: "INFORMATION ONLY"