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Fuel Gauge Reading wrong

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Old Nov 26, 2025 | 08:05 AM
  #1  
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Angry Fuel Gauge Reading wrong

I just put a large capacity (68 Gallon) fuel tank on my 2025 F350 Dully. When i say I, actually I mean I paid the Ford dealership in Gilbert Arizona to do it. The issue is that I think the calibration is off and each time I take it to Ford they say oh, no it is ok, you just need to drive it for a while. Well i have over 1400 miles on it and it still reads low. Actually recently i took it isn for a recall (cluster software update) and they said that was probably causing my issue, the dealership probably reset the tank to a 36 gallon tank, and this made send because a 36 gallon tank would read approximately 576-612 miles to empty when full and my average MPG was between 16 and 17, so i brought it back in and they said it was ok, that the tank capacity was still showing set to a 68 gallon tank, which i find strange as a 68 gallon tank for a truck averaging 16 miles per gallon should be showing should show 1088 mile to empty rather than 611. Actually averaging 17 miles per gallon on a 36 gallon tank would equal 612 mile per gallon, so is this coincidence or is the cahnge to tank capacity not taking affect?

Here is the issue: It is a 68 gallon tank, they say they updated the software to indicate it is a 68 gallon tank and the software does the rest, but when I drive the truck and I am getting an average of 15-17 miles per gallon, and the miles to empty say 75, I stop to refill the tank and I assume I will be putting in about 60 gallons. But 1) when I fill up the tank and after getting 25 gallons in the tank the fuel gauge reads FULL and 611 miles to empty, then 2) the tank takes an additional 26 gallons before the fuel shut off kicks in, indicating there was about 16-17 gallons left in the tank and should have read between 240-272 miles to empty when it read 75 miles to empty.

I had a large capacity tank on my previous SRW F350 and it reacted as you would expect, as soon as average MPG changed the estimate miles to empty updated, just not on this new truck with the new tank. This makes it very nerve racking not knowing and not having confidence on long trips to know i can trust my instruments.

Hs anyone seen this before and does anyone have any ideas what is wrong and what I can do to get the corrected?
 
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Old Nov 27, 2025 | 06:43 AM
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take it in and make them fix it. I'm sure you paid a pretty penny for that 68 gallon tank and install.
 
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Old Nov 27, 2025 | 06:56 AM
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capacity

As of now the 2023 and up are not able to be done. you can change the capacity with forscan or Fords software but the distance to empty is incorrect. S&b has a DTE module coming out to correct this and hopefully the software becomes available
 
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Old Nov 27, 2025 | 08:08 AM
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Use your trip odometer until an update or module is ready. Aim for 60 gallons and 15 mpg. Using your numbers, when your odometer gets to 900 miles, start looking for fuel. You'll still have a nice buffer, plus you can adjust with your mpg accordingly.
 
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Old Nov 27, 2025 | 12:07 PM
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Originally Posted by spares99
I just put a large capacity (68 Gallon) fuel tank on my 2025 F350 Dully. When i say I, actually I mean I paid the Ford dealership in Gilbert Arizona to do it. The issue is that I think the calibration is off and each time I take it to Ford they say oh, no it is ok, you just need to drive it for a while. Well i have over 1400 miles on it and it still reads low. Actually recently i took it isn for a recall (cluster software update) and they said that was probably causing my issue, the dealership probably reset the tank to a 36 gallon tank, and this made send because a 36 gallon tank would read approximately 576-612 miles to empty when full and my average MPG was between 16 and 17, so i brought it back in and they said it was ok, that the tank capacity was still showing set to a 68 gallon tank, which i find strange as a 68 gallon tank for a truck averaging 16 miles per gallon should be showing should show 1088 mile to empty rather than 611. Actually averaging 17 miles per gallon on a 36 gallon tank would equal 612 mile per gallon, so is this coincidence or is the cahnge to tank capacity not taking affect?

Here is the issue: It is a 68 gallon tank, they say they updated the software to indicate it is a 68 gallon tank and the software does the rest, but when I drive the truck and I am getting an average of 15-17 miles per gallon, and the miles to empty say 75, I stop to refill the tank and I assume I will be putting in about 60 gallons. But 1) when I fill up the tank and after getting 25 gallons in the tank the fuel gauge reads FULL and 611 miles to empty, then 2) the tank takes an additional 26 gallons before the fuel shut off kicks in, indicating there was about 16-17 gallons left in the tank and should have read between 240-272 miles to empty when it read 75 miles to empty.

I had a large capacity tank on my previous SRW F350 and it reacted as you would expect, as soon as average MPG changed the estimate miles to empty updated, just not on this new truck with the new tank. This makes it very nerve racking not knowing and not having confidence on long trips to know i can trust my instruments.

Hs anyone seen this before and does anyone have any ideas what is wrong and what I can do to get the corrected?
https://sbfilters.com/products/2023-...libration-tool

I was just thinking/looking this morning.

 
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Old Nov 28, 2025 | 11:48 AM
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This is a known issue for 23+. I seriously doubt your dealer has any tricks to make it work. How about this? Have them set it to 34 gallons (1/2 of your 68) and just double the DTE shown.
 
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Old Nov 28, 2025 | 11:55 AM
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Originally Posted by Monoman67
This is a known issue for 23+. I seriously doubt your dealer has any tricks to make it work. How about this? Have them set it to 34 gallons (1/2 of your 68) and just double the DTE shown.
If they're able to install factory settings, 34, 40, 48 or 66, I would ask for 66.
 
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Old Nov 28, 2025 | 11:58 AM
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Originally Posted by 1olddogtwo
If they're able to install factory settings, 34, 40, 48 or 66, I would ask for 66.
I like that option too. It's like having a 2 gallon reserve tank. ;-)
 
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Old Nov 28, 2025 | 02:15 PM
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Originally Posted by Monoman67
I like that option too. It's like having a 2 gallon reserve tank. ;-)
I texted my dealer and asked him the questions, here's what he said.





 
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