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I'm on my 4th sending unit since January. Just got it back from the dealer last night after they stated that they checked all of the wiring harness', grounds, etc. They even called the Ford HotLine and they didn't have an answer as to why my truck goes thru sending units every 2 months!! Thank God I took it to a dealer to get it replaced the first time!!!
It all started when the fuel gauge only read 3/4 full with a full tank. Took it to the dealer and they said the problem was in the tank, not the gauge. They also said that my stock fuel pump and sending unit was all one unit. Ford changed the design to a separate sending unit and pump so I had to get a new pump, also. While they were taking down the tank the first time, they dropped it and that created a dent. So they gave me a new tank. The new sending units have failed every 2 months since January.
This last time, the mechanic thought my truck had a "slosh module", but the wiring diagrams didn't show one. So they just installed another sending unit and stated that if it happens again, they will call in a Ford engineer. We'll see if that happens!!
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