Fuel tank / pump issue?

Tiny
BROKENEXPLORER
  • MEMBER
  • 2004 FORD EXPLORER
  • 4.0L
  • 4 CYL
  • 4WD
  • AUTOMATIC
  • 115,000 MILES
I bought this truck used and quickly discovered that it runs out of gas with the fuel gage showing 1/4 full.
At first, I figured the gauge was not accurate and I can live with knowing Empty is 1/4 tank. So, after putting in 2 gallons, and got off the side of the road to a gas station. I put in about 10$ worth of gas to get home. Later in the week the truck started to sputter again at a 1/4 tank. Lucky I was near a gas station. This time I filled the tank to the top and found that it would only take 15 gallons max. The owner's guide and web searches confirm that this trunk has a 22.5-gallon fuel tank capacity.
My Question is Where is the other 7.5 gallons hiding?
I now believe the fuel gage is accurate but for unknown reasons the fuel pump won't work at less than a 1/4 full.
I changed the fuel pump relay and fuel filter. Looks to me like the previous owner recently replaced the fuel filter too.

Is there anything else I can do before taking the truck in to replace the fuel pump assembly? This is an expensive repair at the local shop.
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Tuesday, January 17th, 2023 AT 1:24 PM

5 Replies

Tiny
KEN L
  • MASTER CERTIFIED MECHANIC
  • 42,544 POSTS
Yep, the fuel pump is to blame and is the only thing I have heard of that could cause such a problem. Here is a guide to help you change it out or see what needs to be done when doing the job. Here is how the job is done so you know how to do it or what you are paying for.

Fuel Pump, R&R 3.0 hours@ shop rate plus the fuel pump.

Check out the images (below). Please let us know what happens.
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Tuesday, January 17th, 2023 AT 5:36 PM
Tiny
BROKENEXPLORER
  • MEMBER
  • 13 POSTS
One more question related to this issue, I sometimes get a code P0193 "FRP sensor high pressure" after filling the gas tank and the engine stops but restarts and I drive off. What's this about?
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Wednesday, February 1st, 2023 AT 4:48 AM
Tiny
KEN L
  • MASTER CERTIFIED MECHANIC
  • 42,544 POSTS
P0193 Fuel Rail Pressure Sensor Circuit High Input. This may cause the problem because it is related to the fuel system here is the location of the sensor so you can replace it to see if that makes a difference. Check out the images (below). Please let us know what happens.
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Thursday, February 2nd, 2023 AT 1:20 PM
Tiny
BROKENEXPLORER
  • MEMBER
  • 13 POSTS
I needed both a new fuel pump and a pressure sensor. Everything is working fine now, no warning lights. Costed about $800.00 for the repairs.
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Saturday, February 11th, 2023 AT 9:26 AM
Tiny
KEN L
  • MASTER CERTIFIED MECHANIC
  • 42,544 POSTS
Glad you could get it fixed, thanks for letting us know. Please use 2CarPros anytime we are here to help.
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Saturday, February 11th, 2023 AT 2:02 PM

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