So I've been fighting the age old problem with running out of gas at less than 1/4 tank. Dropped the tank 3 months ago and did the "hutch mod". Found the little pick up foot valve popped out. Replaced the foot. Reinstalled the tank and has been working till now.

Driving on the freeway, 60mph engine died. No rpm. Popped it in neutral and cranked it but nothing. I was out of gas again. Fuel gauge said 1/2 tank, Lie-o-meter said 235 MTE. When I was sitting on the side of the road, I could hear the fuel pump cycle with the key on. Bully dog meter showed no psi.

Realized that it was time to fix the sending unit. After it was towed to shop. I tried to research how much they were. $325-400? WTF? I couldn't find any information on a replacement sender. Just the entire pickup assembly. Also could not find any information if the truck unit was a replacement. I could get that for $125. So with a 50/50 shot. I ordered the one for the 03-up ford f250 6.0 diesel. I knew the cluster was the same for 03-04 so why wouldn't the sender be.

I received the pickup unit assembly and compared. 3inches shorter. Slightly longer harness and the float arm was shorter. So I swapped the sending unit. Swapped the foot (why not? It was new) swapped over the float arm and the harness. ( didn't want it to be something stupid like excessive resistance ) All installed and working flawlessly.

So if you don't want a plug and play unit. And are willing to take a few min to save yourself $200. Try it. I'm glad I did.

I took some photos of both units. I'll try to post pics.
Also resistance sweep of the old unit showed it open in several spots.

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Nice write up and info...reps your way...and I still swing a mighty big hammer so ENJOY and thanks for sharing!

 

Thanks for the write up and the initiative to do it yourself!!! And take some pics!!!

 

Do you have the part number for that sending unit?

 

This was the description on ebay. robbob36 was the seller.

This is one brand new genuine Factory Ford Fuel tank sending unit for F250 F350 F450 F550 with 6.0L Diesel engine midship fuel tank with retaining ring style unit ( does not use bolts to mount to tank). The Ford part number is 3C3Z-9275-EA the motorcraft number is PS-139 which was replaced by PS-201 . This unit will also work in place of Ford part number 3C3Z-9275-CA Motorcraft number PS-137 by swapping the float lever arm from the original unit to this unit it just snaps on. This unit comes with float lever and switch fuel sock and check valve as shown in the pictures. We have a limited number of these so don't miss your chance they won't last long. Please feel free to email or call us at 903-546-0024 with any questions about this part or any of our parts. Thanks AAAA Automotive.