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99 & up 7.3L Power Stroke Engine and Drivetrain Discussion of the 99 & up 7.3L Power Stroke diesel engine and drivetrain in the 1999-Up Super Duty trucks and Excursions. No gas engine discussion allowed except on transmissions and drivetrain that pertain to all models. Please confine discussion of topics in this forum to those items that are specific to the 7.3L Power Stroke engine.

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Old 03-28-2010, 11:03 AM   #1 (permalink)
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Fuel tank sending unit

My gauge has been acting up for a while and I think it is the sending unit. I have beat on the side of the tank and checked the wire connectors and it still reads full. I have been running biodiesel for about four years now and that may have possibly done something to the internal wires since it is a solvent. I have located a fuel pickup/sending unit out of a 6.0L for the same long bed 38 gallon tank. From what I can tell the 6.0L unit basically did away with the mixing chamber and internal screens. So my question is...has anyone put one of these units, or a simular unit, in their trucks and just added a water/sediment seperator/filter between the tank and the fuel pump?
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2000 F-350 4x4 CC srw - Tranny/Converter tricked, SCM, Walker BTM, K&N, front end picked up 2"

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2001 F-250 4x2 SC - SCM, Walker BTM, K&N

2001 F-550 6x4 RC - SCM, Walker BTM, K&N

1997 F-250 4x2 SC
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Old 03-28-2010, 04:05 PM   #2 (permalink)
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Have you disconnected and checked the sending unit wires with an ohmmeter? Before you go to the trouble of dropping the tank and replacing something that might still be good (and not fix the problem), you need to check the sending unit operation. With your ohmmeter connected across both wires on the connector, you should get somewhere between 15 and 160 ohms, depending on the tank level. 160 ohms is full and 15 ohms is empty. If it reads somewhere near what you think your fuel level is, then the sending unit is probably OK and your problem is somewhere else (like continuity between the sending uint and the instrument panel or between the sending uint and the ground connection under the dash.)

On the other hand the float could be truly stuck up in the recess where the whole deal mounts. Mine was stuck up there so tightly, no amount of hammering on the tank was going to dislodge it. The float was the first thing to pop out as I raised the unit out of the tank.
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Old 03-30-2010, 05:14 PM   #3 (permalink)
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Got into it today...the bottom black pickup screen had broken off from being brittle and in the tank bottom. The sending unit was somewhat corroded and after taking apart and cleaning, I still could not get a current through the sending unit...I could get one up to where the yellow wire goes into the sending unit prior to where it is soldered. So, it looks like I am in search of a pickup/sending unit since my lead on the other one sold yesterday! I wish I could get just a sending unit and then take the pickup assembly and modify!
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2000 F-350 4x4 CC srw - Tranny/Converter tricked, SCM, Walker BTM, K&N, front end picked up 2"

2000 Excursion Limited 4x2 - SCM, Banks muffler, K&N, nice stereo (400w for the wife), TV's/DVD (for the little ones)

2001 F-250 4x2 SC - SCM, Walker BTM, K&N

2001 F-550 6x4 RC - SCM, Walker BTM, K&N

1997 F-250 4x2 SC
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Old 04-07-2010, 10:03 AM   #4 (permalink)
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Okay, spent some time on it yesterday getting everything adjusted to the correct length and the vent tube cut off. I also noticed the rear vent hose a little damaged so I bought 4' of line and connected the front and rear vents and will additionally put a T near the rear vent to place the plug vent in place.

So, for future reference, the 6.0L pickup/sending unit assembly works like a charm! Mine was for a 29 gallon tank short bed even though I have a 38 gallon tank long bed, but I took some measurements and did a AutoCad drawing to work out how to bend the float rod. The sending unit on the old unit is down low in the tank while the sending unit on the new one is a little over mid tank. I bought this and tried it simply because it was a new Ford Motorcraft unit in the box for relatively cheap...$75! I will try and get some pictures while finishing up today if I am not rushed by the front/rain we have coming in.
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2000 F-350 4x4 CC srw - Tranny/Converter tricked, SCM, Walker BTM, K&N, front end picked up 2"

2000 Excursion Limited 4x2 - SCM, Banks muffler, K&N, nice stereo (400w for the wife), TV's/DVD (for the little ones)

2001 F-250 4x2 SC - SCM, Walker BTM, K&N

2001 F-550 6x4 RC - SCM, Walker BTM, K&N

1997 F-250 4x2 SC
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Old 04-07-2010, 01:46 PM   #5 (permalink)
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I have read alot of posts regarding fuel sending unit issues with Powerstrokes. My 2002
F350's fuel sending unit has an issue. I have the S/C 4x4 short bed 29 gallon tank. When I fill the tank it will read full. When the gauge gets to about 3/4 it will drop back and forth slowly between the 3/4 and 1/2 mark. Then below the 1/2 mark it will stop.

When the truck was still under warranty, I took it to the dealer and to my surprise they couldn't find the problem? They said the gauge wouldn't read showing an issue. I don't know if I have a ground issue or a float issue?
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Old 07-17-2010, 04:18 AM   #6 (permalink)
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Perhaps the problem lies somewhere else. it maybe the gauge itself or the wiring problem.


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AC Delco Fuel Sending Unit - Monitors fuel levels and transmits the information to the fuel gauge; A high quality, direct fit OE replacement fuel sender
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Old 07-17-2010, 08:57 PM   #7 (permalink)
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Yeah, My 02X since Ive owned it was had the mystery fuel gauge problem. Works fine from half to full, then it will get stuck on half and just do nothing. Then it give you a real treat with a full tank and reads E with the light on.Even though the computer display will say 650 miles. The cure my extremely steep drive way. Beats the heck out of me. But when It acts up, up the drive and it works for perfect. It only does it a couple of time a year. The stealer while it was under warranty never could never figure it out. Imagine that. I think it more of a float issue. But who knows. Fill it up reset the trip and you know your good for at least 500 miles.
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Old 07-18-2010, 09:34 AM   #8 (permalink)
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My 2002 F350's fuel gauge would act weird too! When the gauge would get to the 1/2-3/4 point, the gauge would jump around between the two marks. Took it to the dealer while under warranty, the dealer said they could not get the gauge to do that for them. I can bet now if I took the truck in for this again, the dealer would find the cause and give me the bill for the fix since the warranty is gone.
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