Looking for help from you experts! I recently started having a problem with running out of fuel on my 02 7.3 PS Excursion. The first time my milage computer said I had 56 miles, the low fuel light had come on and I had about 1/8th of a tank of fuel when it started sputtering and quit. I added 5 gallons and it started right up but missed for awhile until everything came back to normal. A week later my milage computer said I had 156 miles to go, I had a 1/4 tank of gas and it happened again, this time with no low fuel light on. I added gas and again it missed for awhile until everything returned to normal.
Can anyone give me suggestions as to what may be the problem?

 

Welcome to FTE!!

Sounds like your sending unit may be going bad. If that's it, it's a great opportunity to drop the fuel tank out of the Ex and doa couple of modifications (called the Harpoon and Hutch mods) that will both improve performance and let you replace the sending unit at the same time. Not very hard to do, and therea re planty of good sources for information on the detailed "how-to" on this one.

Whether or not it's actually the sending unit, there are some others here who are more experienced than I and I'm sure they will chime in with helpful information.

 

you sucking air to your fuel system inside those quick connect fittings on the pickup tube inside the tank like F250 said, its a time to drop the tank, and do few mods
get prepaired, buy a kit from ITP here is the link
http://www.itpdiesel.com/store.php?c...on=show_detail
that will take care of you air in fuel problem , and do it asap cause you going to damage you injectors, and will be more money than
hope this helps

 

A common problem with Fords's fuel pickup is that when fuel levels hit around 1/4 full, the "emergency pickup" tied to the mixer screens will allow the pump to pull nothing but air. The in-tank mods eliminate both the mixer assembly and attached duck-bill offending part. It is the orange dohicky in >THIS< pic.

 

I'm not sure, but I think an AE can help alittle with this. I know if you run the tank empty that you should be able to hook up a multimeter and I think check resistance on the sending unit in and out. Someone else might have the diagrams to tell you where and what to read. But AE (Auto Enginuity) is a great diagnostic tool and if your having wiring problems it should help. Lets hope it's the sending unit, keep us informed as you learn more.

 

That information sounds great guys. I guess I don't understand why this problem developed if it is an inherent tank flaw. Wouldn't it have started out having this problem instead of after 120,000 miles? I guess the airleak at the disconnect could develop over time and ofcourse the sending unit could also be going bad. I was told by a friend that used to be a diesel mech that the airspace at the top of the tank was designed for fuel and vapor expansion. What is your feeling on that regarding these mods?

 

Your putting gas in your truck!!! Thats not good for it....lol

 

Parts get distorted, brittle or hard as time goes on.Thousands of trucks, years of time and many, many fuel fillups have shown that there are no ill effects from the harpoon mod.

 

[QUOTE=dsphoto]Wouldn't it have started out having this problem instead of after 120,000 miles?

There is a small bypass valve that opens if the intake screen gets clogged . If that is the case because of where that bypass valve is at ( a few inches above the regular intake) you would run out of fuel and start sucking air at a 1/4 tank or a little less.We just did this mod sat. I got the parts from ITP I also added a low pressure fuel pump between the tank and the new filter . I really feel big difference in the way she runs big improvement pulls harder and runs quieter .