My diesel F250 fuel gauge always seemed to be accurate until recently after it has run completely out of fuel a couple of times. Now the truck runs out of fuel when the gauge reads that it should have a 1/4 of a tank left. I was told that there is some sort of screen that may be clogged in the fuel tank itself that would be causing this problem, however I don't know if this is the case. Any suggestions?

 

It could be the pick-up foot on the bottom of the unit inside the tank. They are knowen for falling off. If u drop the tank to check it out its the perfect time to do the hutch & harpoon mods.

 

The only lubrication that the fuel level sending unit gets is from the diesel sloshing around in the tank. Below about 1/4 tank, the sender starts to get uncovered. Sometimes when my tank gets low before I fill it (low fuel light), it does not read as accurately for anywhere from a few hours to a few days (usually stays on empty). If your truck is not running rough, it just might be the sender. They are not cheap to replace so I just let mine work itself out over a couple of days (I usually go by my trip meter anyway).

I don't know how much you put it, but the meter doesn't respond unless you put more than 8 gallons in the tank (I can't remember where I read it).

 

Had same problem until I replaced the pick-up foot in my tank.
Did the hutch & harpoon mods at the same time.