Ford - Explorer :: 1993 - Fuel Gauge Misreading - Fuel Sending Unit Replacement?


May 18, 2012

I have finally gotten my 93 Explorer back on the road. Now I have a few things that I am trying to get fixed.

The first things that I need to get repaired is my Fuel Sending Unit replaced. How hard is this and what kind of pitfalls am I looking at.

The problem that I am having is that my fuel gauge is never right. The other day I ran out of gas, but the gauge said full. Go firgure.

Anyway I have been told that the problem is my sending unit in the fuel tank. So is there any advise on this repair.

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I've got a 2003 F250, SD, 5.4L Triton that I've owned since new. It has 205,000 kms on it and has run flawlessly since owning it.

Yesterday I went to use the truck after it sitting for about 2 weeks, which isn't uncommon for this time of year as I'm in the landscaping business. It never sits long, though as I make a point of using all the trucks, periodically, just to "blow the stink off" as my Dad would say.

Anyway, when I fired it up the gauge was drop-dead below "E" so I go to fill it up and it takes in fuel and it won't take a drop more. I got under the truck and knocked on the tank in various spots and the tank seems almost plum full.

When I power the truck off and back on, all the gauges come to life and settle on their appropriate readings, except for the fuel gauge. It powers up to full and then drops to below "E" as though I had turned the truck off again.

My question is, am I reasonably safe to assume my sending unit has bitten the dust? I figured that since the gauge comes to life upon startup and then drops to "E" after the rest of the gauges initialize, the fuel gauge itself probably isn't the problem?

Is there a chance that as I drive it over the next few days, and the tank empties, maybe the "sloshing" of fuel might dislodge a stuck part?

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Fuel gauge was working and showing just less than 1/2 tank. Went to Walmart with gift card and started pumping. Got to talking with duramax owner and noticed fuel was finished. did not pop off like the level was high in fill tube just can to end of money..

SO I get in, turn on key to get mileage to mark down miles, gallon, amount etc and noticed the fuel gauge look like it wanted to go up and then it drops to "E" and the fuel light comes on..

Yesterday I drop spare and check sending unit connection which was OK so must be issue with sending unit. ?? So I might need to take camper shell off, fiberglass, and lift bed.. too much fuel in tank and not going to be driving it enough to get down. What size are the bolts holding bed to frame and how do I need do this??

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Dropped the tank, pulled out the pump, and took a close look at the unit; at first, I thought I had play in the bushing as others have found.

However, looking closer, turns out one of the two springed 'tangs' that ride up and down on the potentiometer had broken off, and was not making contact with the board! No amount of fuel additive would have fixed this!

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I had to replace the temp gauge in my 1996 Explorer. I also replaced the sending unit. Now, it is overheating, badly. I replaced the thermostat, twice. Filled the coolant and removed the air in the system. It seems to get good water flow, and there are no coolant leaks. The radiator looks clean, and the cap looks ok. But, as soon as the engine warms up, it goes right past the midline on the gauge all the way to hot - at idle. It gets worse if I drive it. I have grounded the gauge and it seems to be working fine. What could the problem be?

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