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I heard of many SD's doing this. I would take it back to the stealership and have them repair it. Do search and you'll find quite a few threads on this very same subject with some good info
I noticed on my last SD, 99' PSD ,if I left it running while fueling it up,,the gauge took along time to register,,but if it was shut off,,like normal,,when I started it,,all was fine,,!
Fuel Level Less Than Indicated by Fuel Gauge:
Some F-Series and Excursions built between 12-1-02 and 4-14-03 may exhibit an inaccurate fuel level reading after refueling. In most ases this is caused by refueling with the ignition in the on or accessory position. The fuel gauge should eventually reinitialize on its own, but it can also be reinitialized by disconnecting the batteries. If the gauge dose not reinitialize, then the fuel level system should be diagnosed.
Broadcast Message 0926
The same thing has happened to me. I notice that it only happens if the tank fall below the 1/2 mark. Contrary to above, on each occasion my ignition switch was off. It generally takes about an hour for the gauge to reach full.
My truck has done it about 3 times and I always shut it off when I fuel up. But it hasn't done it in a long time, and it always registered correctly after a little while driving so I didn't worry too much about it.
It happened to me when i turned the ignition switch to accessory, to reset the odometer. It corrected itself the next time i started the engine.
You made me remember, I tried to reset mine on accessory-but I think I had to go to "on" in order to get the dash to come to life and I was below half when I fueled.
It is amazing to me how much info I have received from other owners in such a short period of time. The info has been right on the money. Thanks to all who have replied.