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HELP! Fuel sending unit and electrical issues

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Old Jul 24, 2016 | 03:03 PM
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HELP! Fuel sending unit and electrical issues

Hey guys, I really need y'all's help on this. Ever since January My fuel gauge has been acting up big time. I can have any amount of gas in my tank at any given time and the fuel gauge will fall to empty resulting in the fuel and check engine light coming on. The gauge will then return to its position (it still doesn't read correctly) and the check engine light will stay on. I took it to the ford dealer and they said to replace the entire fuel sending unit assembly and quoted me $1,500 for parts and labor so I went to Amazon and bought the oem motorcraft fuel sending unit assembly for $308 and did it myself. The only problem is, I still have the issue. I'm currently checking fuses and relays, PLEASE HELP. By the way, my truck is a 2004 f250 fx4 5.4
 
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Old Jul 24, 2016 | 03:51 PM
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Do you have dual tanks?

 
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Old Jul 24, 2016 | 03:53 PM
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Maybe not, it says "diesel only".
 
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Old Jul 24, 2016 | 03:55 PM
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Go to the store and get them to read the check engine light code. There may be something wrong in the instrument cluster, curious the fuel gauge turns the check engine light on, but all this stuff is interrelated now.
 
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Old Jul 24, 2016 | 03:57 PM
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Here's the fuel gauge circuit.

 
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Old Jul 24, 2016 | 03:58 PM
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In the above diagram you could still have a aux fuel tank. If you do, there may be a problem with that valve that switches the senders.
 
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Old Jul 24, 2016 | 04:01 PM
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I've had them read codes and all they found was one regarding the fuel sending unit, and no I don't have dual tanks.
 
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Old Jul 24, 2016 | 07:38 PM
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Originally Posted by kactus_kyle
I've had them read codes and all they found was one regarding the fuel sending unit, and no I don't have dual tanks.
So you replaced the sending unit, and it still thinks there is something wrong with the sending unit? In that case I would follow the wiring up to the front from the tank looking for problem/frayed/damaged areas. Either that or a loose plug on the cluster.
 
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Old Jul 24, 2016 | 08:19 PM
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Yeah, i just finished checking, cleaning, and di-electric greasing all the connections. I am at a loss for words.... Also, could the fuel tank pressure sensor send a wacky signal to mess up anything or would that be a different code?
 
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Old Jul 24, 2016 | 08:29 PM
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And do you think the cluster could be causing this much trouble?
 
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Old Jul 25, 2016 | 05:53 AM
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Fuel tank pressure sensor would be related to the evap system.

On your truck the cluster is not just a piece of circuit board with lights and gauges mounted in it. It has it's own brain, and talks on the network to the engine computer, body module, abs computer, etc.
 
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Old Jul 25, 2016 | 10:22 AM
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Alright, I'll dig into that soon. Thanks for your help
 
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