Gas Gauge

Hi all,

I have a 98 windstar. Recently, the gas gauge pointed all the way up, way beyond the F (full) mark!!! even though the tank is empty.

I thought it would be the gauge, so I replaced the whole cluster, but the new handle still goes way beyond the F mark.

Any idea to help would be greatly appreciated.

Huynh,
huynh@wans.net

The most likely cause is that the fuel level sender inside the gas tank is faulty. Normally the sender has a resistance of 600 ohms (full) to 0 ohms (empty). When the sender gets worn out, it goes to an infinite resistance which makes the fuel gauge read "fuller than full" as you are seeing. The fix is to drop the fuel tank in order to remove the fuel pump and sender unit. I just did this on my 98 and I went with a junkyard unit which came as a full assembly (pump + sender) that you can just drop in.

You can confirm the diagnosis by disconnecting the wiring harness at the connector located at the front of the gas tank, very close to the fuel filter. I suggest you but the Haynes manual or equivalent -- it's cheap and it gives the full procedure for checking the sender resistance and for replacing the sender, should it come to that.

Thanks a lot, Mr. Ruffy. I just learned something new and very interesting.

I will check the Haynes manual. I replaced the fuel pump (bought at Auto Zone) on 04/2005, and it has life time warranty.

Thanks again.

Huynh,

Hi Mr. Ruffy,
The wire going out from the fuel level sender got short!!! A+++ and "mega" thanks to you.

Well now, you were lucky -- that's much easier than dropping the tank! Glad it worked out.

But, the wire is inside the tank! it got short right after it leaves the sender.
Since your explanation was knowledgable, I went on and took the tank off without checking the connector. The pump is garranteed for 999 years, so I exchanged a new one. Thanks again.