I have an intermitent problem with my fuel gauge. It works good most of the time and then it reads completley empty with the warning light on. The problem comes and goes with no reason that I can see, At the same time the thermometer reads about 20 degrees low, all other reading seem to be OK. This is in a 04 550 6.0 diesel. Any Ideas? Thanks, Jim

 

after I had done the egr cooler and oil cooler repair my truck set a while. When we got it finally fired up, i had the same problem. After disconnecting the batteries a few times and a couple bottles of "diesel clean", it just went away and hasn't happen anymore.

 

How many miles on your rig? I had problems with the fuel gauge just dropping to nothing with a low fuel alert, regardless of the true tank level. After over 10,000 miles of searching, it was the instrument cluster. You can try Techron. There are some past postings to search also on this. One of the "rules" is to not keep her running while filling up.

 

I'm running into the same issue again. Pulled a P0460 ( fuel level sensor ) I had the truck in the shop twice for this.
This time my truck sat for 4 days. Started normal. drove down the road ( truck has 1/4 of a tank fuel) fuel gauge drops low fuel light comes on,and CEL is on .. LOL GEEZ not again.. kept driving . Fuel gauge shoots up to full .Drive a few more miles .Then drops to where it should be. CEL still on...
Truck is out of warranty.Has anybody else had ,and or fixed this problem? Any techs out there that can help me? I dont want to be stranded on the side of the road with my kids ,cause I ran out of fuel due to bad gauge.

 

I have an 07 with this problem. I checked the the sender with an analog ohm meter on pins 8 and 10 on the blue connector that plugs into the instrument cluster and it seems consistent. I read that there is a TSB for this issue ( 06-5-10***MIL ON WITH DTC P0460 - 6.0L ) so I took it to the dealer to see if the software was up to date. I got the truck back and they said the software was good and that the fuel sender was faulty. I doubted that the sender was faulty but i swapped it out with a known good sender and i still have the same problem. I took the truck for a long drive to see if the problem would sort itself out. the gauge now works most of the time but still drops to empty intermittently and the P0460 will not erase even with the gauge reading correctly. I believe its possibly a software issue with the instrument cluster or a problem with the PCM. The truck only has 64,000kms on it so I am going to see what Ford is willing to do. An Instrument cluster is $500 and a PCM is $1000 which I think is a bit excessive just to have a functioning fuel gauge.

 

Try cleaning your positive terminals on both batteries. Advanced sells terminal cleaner that neutralizes corrosion on battery terminals. Is red when sprayed and turns yellow when activated on corrosion. 95% of the time fuel gauge will read low fuel or show gas all the way full even though you know it isn't. Clean the positive teminals and check. I can almost guarantee that will solve your problem with fuel gauge acting up out of the blue.

 

Bump for related issue:

I recently had my fuel tank replaced on my 2013 6.7 to a larger titan one, it worked fine at first and now on my first 60 gal fill, it is now stuck on full. The DTE was unknown since it was over 999. Now it has ticked down to around 950mi. The fuel gauge is still pegged on full. I have used around 10 gallons almost so far on this tank. At one point it showed the gauge right at the f tickmark which is around 1/8 in below the full pegged mark. Then i noticed it went to full pegged. I believe it should be just under the full mark and above the 3/4 tank but it just is pegged to full constantly now. I can try cleaning the battery terminals but nothing has changed under the hood. Also I checked with forscan and no new codes have popped, a couple are popped that have been there since I bought the truck a few years ago. Are there wires i should check that run to the instrument cluster? What wires and what should the reading be? Is there a way to reset the computers or something by disconnecting batteries? It is still mostly full so I am not going to be able to drop the tank for a few weeks to check that if it is a possibility. The first fill with fuel jugs was under half way and the gauge read what seemed to be accurate.

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