Fuel Gauge - Occasionally Sticks In FULL Position

89ford21

GAUGE-FUEL-OCCASIONALLY STICKS IN "FULL" POSITION

Article No. 89-14-11

FORD: 1989 THUNDERBIRD

LINCOLN-MERCURY: 1989 COUGAR


ISSUE: A fuel gauge that ocassionally sticks in the "FULL" position may be caused by a binding fuel pump float assembly. The fuel pump float binds on the inner surface of the fuel tank and holds the float in the "FULL" position. This is most likely to occur when driving on unpaved or rough roads.

ACTION: Modify the fuel pump float to prevent the binding condition. Refer to the 1989 Thunderbird/Cougar Shop Manual, Section 24-12 for removal and installation instructions.

1. Remove the fuel pump assembly.

2. Unscrew the nut from the end of the float rod assembly.

3. Remove the float from the rod.

4. Using a sharp knife, cut 3/8" to 1/2" (9.525 mm to 12.7 mm) off the end of the float.

5. Reinstall the shortened float on the float rod.

6. Install float retaining nut.

NOTE: ALLOW CLEARANCE BETWEEN THE RETAINING NUT AND FLOAT SO THAT THE FLOAT SPINS FREELY.

7. Using diagonal cutters, trim the float rod so that it is flush with the retaining nut.

8. Reinstall the fuel sender.

OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: Eligible Under Basic Warranty Coverage

OPERATION DESCRIPTION TIME
891411A Modify Float 1.3 Hrs.

DEALER CODING
BASIC PART NO. CONDITION CODE
9H307 41
OASIS CODES: 2300, 2310, 2400