Update: I pulled the tank out of my flex and set it on the ground. I pulled out both the pump/sending unit and the secondary sending unit as well as the crossover hose that links the two.
Btw, you can see from picture of underside of flex, ford only put one access panel in so I recommend you drop the tank cuz I’ve seen YouTube videos where people are cutting holes in their floor to gain access. Not a good idea.
I was looking for any cracks in lines or fittings. I found none. I replaced all 3 items. I checked new ohm values of new floats. They are 10 ohms to 180 ohms.
I checked the old units and while they were 10 ohms to 180 ohms there was a couple spots that were a little intermittent. I’ve asked a friend at ford dealer to ask a tech if the computer will get faked out if these resistance readings flake out because the first time I ran out of gas the car said I had 60 miles to empty. The second time it showed I had 120 miles to empty. After I filled the tank and reset everything I drove till it said I had 120 miles to empty and that is when I pulled tank. I siphoned 6 to 6-1/2 gallons out of tank which jived with the computer saying 120 miles to empty and I get 20-21 mpg.
Both times when I ran out of gas the gauge was on 1/4 tank and the computer said I had 60 and 120 miles to empty and I literally watched the gauge drop to zero and the miles drop to zero and within 30 seconds the car died and I had to call a friend to bring me some gas.
After I replaced all three items in the tank cuz I figured I didn’t want to mess with any of the pain in the butt of pulling the tank again….
So after I replaced everything and re-installed the tank I put back the 6 to 6-1/2 gallons of gas in tank and the started the car. The computer said I had 120 miles to empty which is same as before I started.
I drove it till it showed I had 20 miles to empty and I never ran out of gas. When I filled up it took 17.7 gallons which made sense with the fact that I had a 18.6 gallon tank. All the math came out right.
And not only did the gas gauge continue to work below 1/4 tank,the miles to empty dropped linear and I got both the 50 miles to empty warning beep and the 25 miles to warning beep.
So it seems like the problem was fixed and I’m 99% sure it was probably one of the floats/wipers feedback linear resistors on sending units since I found no other issues.
Btw, you can see from picture of underside of flex, ford only put one access panel in so I recommend you drop the tank cuz I’ve seen YouTube videos where people are cutting holes in their floor to gain access. Not a good idea.
I was looking for any cracks in lines or fittings. I found none. I replaced all 3 items. I checked new ohm values of new floats. They are 10 ohms to 180 ohms.
I checked the old units and while they were 10 ohms to 180 ohms there was a couple spots that were a little intermittent. I’ve asked a friend at ford dealer to ask a tech if the computer will get faked out if these resistance readings flake out because the first time I ran out of gas the car said I had 60 miles to empty. The second time it showed I had 120 miles to empty. After I filled the tank and reset everything I drove till it said I had 120 miles to empty and that is when I pulled tank. I siphoned 6 to 6-1/2 gallons out of tank which jived with the computer saying 120 miles to empty and I get 20-21 mpg.
Both times when I ran out of gas the gauge was on 1/4 tank and the computer said I had 60 and 120 miles to empty and I literally watched the gauge drop to zero and the miles drop to zero and within 30 seconds the car died and I had to call a friend to bring me some gas.
After I replaced all three items in the tank cuz I figured I didn’t want to mess with any of the pain in the butt of pulling the tank again….
So after I replaced everything and re-installed the tank I put back the 6 to 6-1/2 gallons of gas in tank and the started the car. The computer said I had 120 miles to empty which is same as before I started.
I drove it till it showed I had 20 miles to empty and I never ran out of gas. When I filled up it took 17.7 gallons which made sense with the fact that I had a 18.6 gallon tank. All the math came out right.
And not only did the gas gauge continue to work below 1/4 tank,the miles to empty dropped linear and I got both the 50 miles to empty warning beep and the 25 miles to warning beep.
So it seems like the problem was fixed and I’m 99% sure it was probably one of the floats/wipers feedback linear resistors on sending units since I found no other issues.