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I am hoping someone "in the know" can settle this dilemma: Will running the van with less than a quarter of a tank of fuel over a long period of time burn out the electric fuel pump? I have read that gasoline actually acts as a "coolant" for the pump. Personally, I have been keeping my Aerostar's tank on or near full all the time, simply because of how much it costs to full up an empty tank with today's gas prices. Any way, should the tank be kept full, or is running it low and eventually burning out the fuel pump sooner as opposed to later simply not true?
I changed the pump in my Aerostar two years ago. The tank was near empty (about 1-2 gallons left inside)when I dropped it. I recall when I pulled the unit with sender and pump out of the tank, the pump was wet outside. Although I did not look inside the tank (strike a match :-( ) I am sure there must be some niche inside forming a low point where the rest of the fuel gets together. Otherwise, you'd run out of gas much sooner since the tank is pretty long.
Anyway, there was an instruction leaflet that came with the new pump. According to the leaflet, the pump is cooled by the fuel running through it. It said the pump is not to be run without fuel or else it would overheat.
I think you can run your Aerostar on low fuel and the only thing you have to fear is to get stranded with an empty tank.
Tom
1993 Aerostar XL 3.0L Extended
Munich, Germany
Running the tank empty will damage the electric fuel pump, but as long as there is some fuel to help cool and lubricate the pumps parts, no damage should occur. Just don't let the tank run empty and the pump dry. Keeping it near full isn't necessary but if you live in a colder climate, keeping the tank more full then empty will stop moisture from condensing out in the tank and allowing rust to form and water to get into the gas. The Aerostar uses a plastic tank but corrosion of other parts is possible and this is a good idea on any vehicle.