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1987 - 1996 F150 & Larger F-Series Trucks 1987 - 1996 Ford F-150, F-250, F-350 and larger pickups - including the 1997 heavy-duty F250/F350+ trucks

I MUST BE GOING CRAZY???

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Old Apr 1, 2015 | 11:55 AM
  #1  
Jonnys.1991's Avatar
Jonnys.1991
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I MUST BE GOING CRAZY???

Crazy but True Story...
My ’91 F150 has duel fuel tanks. My fuel gauge showed ¼ full front tank. I when to fill up the front tank and it would only hold a couple of gallons as gas. Not knowing if I needed any fuel in my rear tank, I when to fill it up too and as soon as I twisted the cap off, gas went everywhere. Any idea what is going on??
 
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Old Apr 1, 2015 | 12:55 PM
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Originally Posted by Jonnys.1991
Crazy but True Story...
My ’91 F150 has duel fuel tanks. My fuel gauge showed ¼ full front tank. I when to fill up the front tank and it would only hold a couple of gallons as gas. Not knowing if I needed any fuel in my rear tank, I when to fill it up too and as soon as I twisted the cap off, gas went everywhere. Any idea what is going on??
Just a guess here. Each fuel tanks has two fuel lines. The supply line from the in-tank pump goes to a high pressure pump to feed the EFI, and a return line returns any gas not consumed by the engine.

With dual tanks, both of these fuel lines from each tank goes to a 4-way tank selector valve which connects the pair (supply/return) of lines (4 lines total) to the high pressure fuel pump and return line on the engine side of the valve (2 lines).

theory 1) Somebody inadvertently switched the return lines from the front and rear tanks. This would pump any return gas to the wrong tank.

theory 2) The valve is leaking somehow and accidentally is flowing the return fuel to the wrong tank, or to both tanks (the return valve is leaking internally and connecting the EFI fuel return to both return lines).

theory 3) Somebody tried to go cheap and replaced the stock 4 way valve with a 2 way valve and just put a T to connect the return lines to both the tanks.

If the system used to work fine before and you haven't done any recent repair to the fuel system, I'd bet on theory 2.
 
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Old Apr 1, 2015 | 01:10 PM
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Well theory 1 & 3 are out, as I have owned this truck since new and I do all my own work. You may have something there with the selector valve. I will do a little more checking on it. Thanks, Jon.
 
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Old Apr 1, 2015 | 05:38 PM
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1991 model year gas engine trucks do not have a selector valve. Each tank has it's own high pressure pump and check valves.

The rear tank has a bad check valve in the Fuel Delivery Module.

The front tank probably has a fuel sender float with a hole in it. Fuel gets in and makes it sink....
 
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Old Apr 1, 2015 | 05:45 PM
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^^^^What he said!!^^^^^^
 
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Old Apr 1, 2015 | 05:53 PM
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Damn...more than one thread for the same problem.....https://www.ford-trucks.com/forums/1...ve-or-not.html


(%^*(%^&*()
 
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Old Apr 1, 2015 | 10:31 PM
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lol + 7 characters.
 
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Old Apr 2, 2015 | 07:49 AM
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Thanks, for the help Guys.
 
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