how to fix the Ford Explorer Sixth Generation (2020-present) fuel gauge not working

Ford Explorer Sixth Generation (2020-present)

Error Codes

2-4 hours

Time

medium

Difficulty

medium

Severity

3 min read

593 words

Problem Statement

Learn how to diagnose and fix the fuel gauge not working issue in Ford Explorer (2020-present). Step-by-step guide with diagnostic procedures and repair instructions.

Affected Component

Fuel System

Estimated Time

2-4 hours

⚠️ Safety Warnings

Important safety information - read before proceeding

•Disconnect battery before working on electrical systems.
•Relieve fuel pressure before disassembling any fuel system components.

Symptoms

•Fuel gauge needle remains at empty or does not move
•Check engine light illuminated
•Erratic fuel gauge readings (jumps or fluctuates unexpectedly)
•Fuel warning light activates prematurely
•Difficulty estimating remaining fuel, leading to potential stalling

Diagnostic Steps

1
Scan the vehicle's onboard computer with an OBD-II scanner for error codes related to the fuel system.
2
Inspect the fuel gauge wiring and connectors for loose connections or visible damage.
3
Check the fuel level sensor in the fuel tank for proper operation using a multimeter.
4
Verify the functionality of the instrument cluster by performing a cluster test, if available.
5
Inspect the fuel pump relay and fuse for any signs of failure.
6
Measure fuel pressure at the fuel rail to ensure the fuel pump is functioning correctly.

Solution

💡 Expert Tip

For complex repairs like this, consider taking photos at each step. This helps if you need to reverse a step or consult with a mechanic. Also, keep all removed parts organized - you may need to reference them during reassembly.

Verification

After completing the repair, verify that the issue has been resolved:

✓Test the affected component to ensure it functions correctly
✓Check for any error codes or warning lights
✓Monitor the vehicle for a few days to ensure the issue does not recur

Prevention Tips

To prevent this issue from occurring again:

•Follow the manufacturer's recommended maintenance schedule
•Address warning signs early before they develop into major issues
•Use quality parts and fluids recommended for your vehicle
•Keep detailed records of all repairs and maintenance

Tools & Equipment Required

•OBD-II scanner
•Multimeter
•Socket set
•Flathead screwdriver
•Safety glasses
•Gloves

Parts Required

•Replacement fuel level sensor
•Fuel pump assembly gasket (if needed)

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Diagnostic Steps

1
Scan the vehicle's onboard computer with an OBD-II scanner for error codes related to the fuel system.
2
Inspect the fuel gauge wiring and connectors for loose connections or visible damage.
3
Check the fuel level sensor in the fuel tank for proper operation using a multimeter.
4
Verify the functionality of the instrument cluster by performing a cluster test, if available.
5
Inspect the fuel pump relay and fuse for any signs of failure.
6
Measure fuel pressure at the fuel rail to ensure the fuel pump is functioning correctly.

Solution

1. Preparation

Gather necessary tools and parts.
Disconnect the negative battery terminal to ensure safety.
Allow the vehicle to cool if it has been running.

2. Remove the Fuel Pump Assembly

Tools Required: Socket set, flathead screwdriver, safety glasses, gloves.
Sub-steps:
1. Relieve fuel system pressure by removing the fuel pump fuse and running the engine until it stalls.
2. Disconnect the battery negative terminal.
3. Remove the rear seat or access panel to expose the fuel pump cover.
4. Unscrew the fuel pump cover retaining screws and carefully lift the cover.
5. Detach the electrical connector and fuel lines from the fuel pump assembly.
6. Remove the pump assembly from the tank (may require turning it slightly to disengage).

3. Inspect and Replace Fuel Level Sensor

Tools Required: Multimeter, replacement fuel level sensor, cleaning cloth.
Sub-steps:
1. Use a multimeter to test the resistance of the fuel level sensor. Compare readings with manufacturer specifications.
2. If the sensor is faulty, replace it with a new one.
3. Clean any debris from the fuel tank before reinstallation.

4. Reinstall Fuel Pump Assembly

Tools Required: Socket set.
Sub-steps:
1. Position the fuel pump assembly back into the tank, ensuring it fits securely.
2. Reconnect the fuel lines and electrical connector.
3. Reinstall the fuel pump cover and secure it with screws.
4. Reinstall the rear seat or access panel.

5. Reconnect Battery and Test

Sub-steps:
1. Reconnect the negative battery terminal.
2. Install the fuel pump fuse back into its holder.
3. Start the engine and check if the fuel gauge is functioning correctly.
4. Monitor for any error codes with the OBD-II scanner.