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1994.5 - 1997 7.3L Power Stroke Diesel  

fuel guage issue

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Old Aug 28, 2025 | 07:10 PM
  #1  
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sbraatz
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fuel guage issue

After dealing with a front tank fuel guage that I could no longer trust to give me an accurate reading of how my fuel consumption was going, I decided it was time to drop the
front tank and see what's what. The float had a pin hole and the shower head hadn't fallen apart yet but was on its way. Replace the float assembly and new shower head. Reinstalled the
tank and added new fuel - now the tank registers full well beyond the full mark on the dash. Never had this issue with the original parts - the guage barely moved after a 150 miles - ran the tank dry at 275 miles and the guage registered 1/2 tank... Switched to the rear which reads as it should - being that I can't live with things that don't work as they should, I dropped the front tank again. Replaced the float assembly with a Ford OEM and filled the tank and went for another drive to test the guage/float. Long story short - same results! Can't for the life of me figure out what in the H--- is going on. Is there a calibration that I'm missing? Any of you gurus out there have a fix for my frustration. Thank as always for the advice from the forum guys.

Any body out there have
 
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Old Aug 29, 2025 | 09:24 AM
  #2  
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From: Bahstun
Did you test the float prior to installing the tank into the truck?
Only need an ohm meter.
  • Empty: Around 15-16 ohms
  • Full: Approximately 160 ohms
Sometimes you have to bend the rod some to your liking.
 
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Old Aug 29, 2025 | 10:25 AM
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No. I did not Ohm test the float. I'll get to it when I drop the tank again. Not looking forward to doing that again.
I'll probably get to it in a couple of weeks. Other house projects will keep me occupied till then.
 
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Old Sep 23, 2025 | 11:47 PM
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Well, I sucked it up and attacked the fuel guage / tank issue, again. Took the truck to a friends shop to get the truck up on the lift. Upon dropping the tank once again and doing a Ohm test, it all checked out to spec. Found a loose connection under and behind the dash that was causing a bit of increased resistance, causing the guage to read a bit wonky. Cleaned the connection and problem solved. Glad that's done. Now I can look forward to long road trips ponce again. My bucket trip is to drive to Alaska along the Alcan Highway. Planning and hoping that it all works out two years from now. Need to convince my wife that this is a worthwhile trip.. Just returned from our 6th cross country trip (8900 mi) in our other vehicle (due to the truck guage issue) but this is bigger mountain to climb. Going to AAA to get maps (trip tic) and begin the planning of the route and sites to see along the way. Fingers crossed. Any one out there make this trip?
 
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Old Sep 24, 2025 | 09:56 AM
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From: Bahstun
Glad to hear your made progress. Take some pics of that trip and post here
 
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Old Oct 28, 2025 | 01:07 PM
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Originally Posted by sbraatz
Well, I sucked it up and attacked the fuel guage / tank issue, again. Took the truck to a friends shop to get the truck up on the lift. Upon dropping the tank once again and doing a Ohm test, it all checked out to spec. Found a loose connection under and behind the dash that was causing a bit of increased resistance, causing the guage to read a bit wonky. Cleaned the connection and problem solved. Glad that's done. Now I can look forward to long road trips ponce again. My bucket trip is to drive to Alaska along the Alcan Highway. Planning and hoping that it all works out two years from now. Need to convince my wife that this is a worthwhile trip.. Just returned from our 6th cross country trip (8900 mi) in our other vehicle (due to the truck guage issue) but this is bigger mountain to climb. Going to AAA to get maps (trip tic) and begin the planning of the route and sites to see along the way. Fingers crossed. Any one out there make this trip?
I'm having the same issue but can't find any wiring issues. Can you elaborate on where "under and behind the dash" you found your issue?
 
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