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Is it possible for the engine to suck one tank dry and start taking fuel from the other tank without switching it on the dash?..I have a 96 extended cab and just took it for my first fairly long trip with both tanks full.I was using the front tank and made it almost home before the needle said empty so I thought I would just leave it and see if I could make it on the one tank(and also check the gauge accuracy).I made it home no problem,the engine never sputtered or quit but when I switched to the rear tank the needle wasn't quite showing full anymore.
My '87 does the same thing. I have replaced the dual tank reservoir, which I would think should prevent that from happening, but apparently not so. I'm not sure what year Ford switched from the system I have (the dual tank reservoir) and the later system with checkvalves, so I don't know if you have the same as me or not. Since my system is pressure operated, I wonder if the high-pressure pump could draw gas from the full tank even if it wasn't selected.
it's not unheard of. There was a recall on the tank switching mechanism. One tank could pump into the other and overflow. I had a hole in my rear tank. I ran it dry several times, but it would always collect gas from the front tank. I'm guessing the return lines have something to do with it. I haven't bothered to look into it any further as it hasn't caused me any trouble.
Prior to 1990, when they were using the single external high pressure pump, it was possible to draw gas from both, but it was not normal behavior. There is no way to get it to automatically fail over to the full tank.
After 1990, though, it's not even remotely possible. The in-tank pump puts out the pressure, and unless there are serious electrical problems, they both can't be running.
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