2005 Ford F-250 Fuel Gauge

Tiny
RODTHEDRILLER
  • MEMBER
  • 2005 FORD F-250
  • V8
  • 4WD
  • AUTOMATIC
  • 160,000 MILES
I filled my truck up and gauge stays on empty. How does this work is it a float in the tank that might be stuck or a senscer that has to be replaced. I suppose it is in the tank. Any suggestions as where to start?
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Friday, October 1st, 2010 AT 1:04 PM

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Tiny
MERLIN2021
  • EXPERT
Fuel Gauge The instrument cluster receives the fuel level signal from the fuel level sensor, part of the fuel tank unit. The fuel level sensor measures variable resistance in the fuel tank depending on the current fuel level. When the fuel level is low, the resistance in the unit is low (15 ohms +/- 2 ohms). When the fuel level is high, the resistance in the unit is high (160 ohms +/- 4 ohms). The instrument cluster uses 4 different operating modes to calculate the fuel level: anti-slosh (default mode) key OFF fueling key ON fueling recovery After a fuel fill up, the time for the fuel gauge to move from empty (E) to full (F) ranges from 2 seconds to 55 minutes depending on which operating mode the fuel gauge is in. The default fuel gauge mode is called the anti-slosh mode. To prevent fuel gauge changes from fuel slosh (gauge instability due to changes in fuel sender readings caused by fuel moving around in the tank), the fuel gauge takes approximately 55 minutes to go from full (F) to empty (E). The key OFF fueling mode (2 seconds to read empty [E] to full [F]) requires 3 conditions be met: The key must be in the OFF position when refueling the vehicle. At least 15 percent of the vehicle's fuel capacity must be added to the fuel tank. The instrument cluster must receive a valid key ON fuel sender reading within 1 second of the key being put into the RUN position. The key ON sample readings are considered valid if the fuel sender reading is between 15 ohms +/- 2 ohms and 160 ohms +/- 4 ohms. If these conditions are not met, the fuel gauge stays in the anti-slosh mode, which results in a slow to read full (F) event. The key ON fueling mode (approximately 90 seconds to read empty [E] to full [F]) requires 3 conditions be met: The transmission is in park (P) (automatic transmissions), or the parking brake applied (manual transmissions). The key is in the RUN position. At least 15 percent of the vehicle's fuel capacity must be added to the fuel tank. In key ON fueling mode, a 30 second timer activates after the transmission is put into the park (P) position (automatic transmissions) or when the parking brake is applied (manual transmissions). When the 30 second time has elapsed and at least 15 percent of the vehicle's fuel capacity has been added, the fuel gauge response time is 90 seconds to read from empty (E) to full (F). When the transmission is shifted out of park (P) or the parking brake is released, the fuel gauge strategy reverts NOTE: It is critical to follow the pinpoint test diagnostic methods to make sure the correct mode is being used during diagnostics. to the anti-slosh mode. This mode prevents slow to read full events from happening if the customer refuels the vehicle with the key in the RUN position. Recovery mode is incorporated into the instrument cluster strategy to recover from a missing fuel level message during a refueling event. Missing fuel level messages result from intermittent opens in the fuel sender or its circuits. Recovery mode (empty [E] to full [F] approximately 20 minutes) is initiated when the following 2 conditions are met: The instrument cluster is in the anti-slosh (default) mode. The actual fuel level in the tank is greater than what is being displayed by the fuel gauge.

Testing:
PINPOINT TEST B: INCORRECT FUEL GAUGE INDICATION B1 CARRY OUT THE INSTRUMENT CLUSTER FUEL GAUGE ACTIVE COMMAND USING THE DIAGNOSTIC TOOL Key in ON position. Enter the following diagnostic mode on the diagnostic tool: Instrument Cluster Active Command. Select the instrument cluster active command. Trigger, monitor, and scroll the fuel gauge level at 0%, 50%, and 100%. Does the fuel gauge display below E with 0%, half with 50%, and full stop with 100%? Yes : GO to B2. No : GO to B7. B2 CHECK THE FUEL GAUGE OPERATION Key in OFF position. Remove the central junction box (CJB) fuses 2 (10A), 35 (10A) and 41 (10A). Wait 1 minute and reinstall the fuses. Disconnect: Fuel Tank Unit C434 (Pickup) or C4033 (Chassis Cab). Connect 1 lead of the instrument gauge system tester to the fuel tank unit C434-2 (pickup) or C4033-5 (chassis cab), circuit 29 (YE/WH), harness side and the other lead to the fuel tank unit C434-4 (pickup) or C4033-8 (chassis cab), circuit 396 (BK/OG), harness side. Fig. 3: Checking Fuel Gauge Operation Courtesy of FORD MOTOR CO. Key in ON position. On vehicles equipped with an automatic transmission, apply the brake and move the transmission shift lever from P (park) to D (drive). Wait 10 seconds, and move the transmission shift lever back to P (park). Wait 30 seconds. On vehicles equipped with a manual transmission, apply the parking brake. Wait 10 seconds, and release the parking brake. Wait 30 seconds. Do not change the tool settings or the ignition switch position until 30 seconds have elapsed. Key in OFF position. Set the tester to 160 ohms. Key in ON position. On vehicles equipped with an automatic transmission, apply the brake and move the transmission shift lever from P (park) to D (drive). Wait 10 seconds, and move the transmission shift lever back to P (park). Wait 30 seconds. On vehicles equipped with a manual transmission, apply the parking brake. Wait 10 seconds, and release the parking NOTE: The fuses must be removed to reset the fuel gauge timers. Failure to complete this step may result in erroneous test results. brake. Wait 30 seconds. Do not change the tool settings or the ignition switch position until 30 seconds have elapsed. Key in OFF position. Wait 30 seconds. Do not change the tool settings or the ignition switch position until 30 seconds have elapsed. Set the tester to 15 ohms. Key in ON position. On vehicles equipped with an automatic transmission, apply the brake and move the transmission shift lever from P (park) to D (drive). Wait 10 seconds, and move the transmission shift lever back to P (park). Wait 30 seconds. On vehicles equipped with a manual transmission, apply the parking brake. Wait 10 seconds, and release the parking brake. Wait 30 seconds. Do not change the tool settings or the ignition switch position until 30 seconds have elapsed. Observe the fuel gauge. The fuel gauge should read E (empty) or below. Key in OFF position. Wait 30 seconds. Do not change the tool settings or the ignition switch position until 30 seconds have elapsed. Set the tester to 160 ohms. Key in ON position. Observe the fuel gauge. The fuel gauge should read F (full ) or above. Does the fuel gauge operate correctly? Yes : DISCONNECT the instrument gauge system tester. GO to B3. No : DISCONNECT the instrument gauge system tester. GO to B4. B3 CHECK THE FUEL TANK Check the fuel tank for any damage or deformation. Is the fuel tank OK? Yes : INSTALL a new fuel tank unit. REFER to FUEL TANK AND LINES - GASOLINE AND DIESEL . CLEAR the DTCs. REPEAT the self-test. No : INSTALL a new fuel tank. REFER to FUEL TANK AND LINES - GASOLINE AND DIESEL . CLEAR the DTCs. REPEAT the self-test. B4 CHECK CIRCUITS 29 (YE/WH) AND 675 (YE/LB) FOR A SHORT TO VOLTAGE Disconnect: Instrument Cluster C220b. Key in ON position. For vehicles equipped with a single fuel tank, measure the voltage between the instrument cluster C220b-10, circuit 29 (YE/WH), harness side and ground. Fig. 4: Checking Circuits 29 (YE/WH) And 675 (YE/LB) For Short To Voltage (Single Fuel Tank) Courtesy of FORD MOTOR CO. NOTE: Wait 1 minute for the fuel gauge to respond. For vehicles equipped with dual fuel tanks, measure the voltage between the instrument cluster C220b-9, circuit 675 (YE/LB), harness side and ground. Fig. 5: Checking Circuits 29 (YE/WH) And 675 (YE/LB) For Short To Voltage (Dual Fuel Tank) Courtesy of FORD MOTOR CO. Is any voltage present? Yes : REPAIR the circuit in question. CLEAR the DTCs. REPEAT the self-test. No : GO to B5. B5 CHECK CIRCUITS 29 (YE/WH) AND 675 (YE/LB) FOR AN OPEN OR A SHORT TO GROUND For vehicles equipped with a single fuel tank, measure the resistance between the instrument cluster C220b-10, circuit 29 (YE/WH), harness side and the fuel tank unit C434-2 (pickup) or C4033-5 (chassis cab), circuit 29 (YE/WH), harness side; and between the instrument cluster C220b-10, circuit 29 (YE/WH), harness side and ground. Fig. 6: Checking Circuits 29 (YE/WH) And 675 (YE/LB) For Open Or Short To Ground (Single Fuel Tank) Courtesy of FORD MOTOR CO. Disconnect: Primary Fuel Tank Unit C3094. For vehicles equipped with dual fuel tanks, measure the resistance between the instrument cluster C220b-9, circuit 675 (YE/LB), harness side and the primary fuel tank unit C3094-2, circuit 675 (YE/LB), harness side; and between the instrument cluster C220b-9, circuit 675 (YE/LB), harness side and ground. Fig. 7: Checking Circuits 29 (YE/WH) And 675 (YE/LB) For Open Or Short To Ground (Dual Fuel Tank) Courtesy of FORD MOTOR CO. Is the resistance less than 5 ohms between the instrument cluster and the fuel tank unit, and greater than 10,000 ohms between the instrument cluster and ground? Yes : GO to B6. No : REPAIR the circuit in question. CLEAR the DTCs. REPEAT the self-test. B6 CHECK CIRCUIT 396 (BK/OG) FOR AN OPEN OR A SHORT TO GROUND Measure the resistance between the instrument cluster C220b-8, circuit 396 (BK/OG), harness side and the fuel tank unit C434-4 (pickup), or C4033-8 (chassis cab), circuit 396 (BK/OG), harness side; and between the instrument cluster C220b-8, circuit 396 (BK/OG), harness side and ground. Fig. 8: Checking Circuit 396 (BK/OG) For Open Or Short To Ground Courtesy of FORD MOTOR CO. Is the resistance less than 5 ohms between the instrument cluster and the fuel tank unit, and greater than 10,000 ohms between the instrument cluster and ground? Yes : GO to B7. No : REPAIR the circuit. CLEAR the DTCs. REPEAT the self-test. B7 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION Disconnect all the instrument cluster connectors. Check for: corrosion pushed-out pins Connect all the instrument cluster connectors and make sure they seat correctly. Operate the system and verify the concern is still present. Is the concern still present? Yes : INSTALL a new instrument cluster. REFER to INSTRUMENT CLUSTER . TEST the system for normal operation. No : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. CLEAR the DTCs. REPEAT the self-test.


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I will send you the cluster self test so you can see if any fuel gauge codes are present.
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Friday, October 1st, 2010 AT 1:09 PM

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