how to fix the fuel gauge not working in Ford Explorer Fifth Generation (2011-2019)

Ford Explorer Fifth Generation (2011-2019)

Error Codes

2-4 hours

Time

medium

Difficulty

medium

Severity

3 min read

567 words

Problem Statement

Learn how to diagnose and fix the fuel gauge issue in Ford Explorer (2011-2019). Step-by-step guide with symptoms, diagnostic steps, and repair instructions.

Affected Component

Fuel System

Estimated Time

2-4 hours

⚠️ Safety Warnings

Important safety information - read before proceeding

•Disconnect the battery before working on electrical systems.
•Allow the fuel system to depressurize before disconnecting fuel lines.

Symptoms

•Fuel gauge reading empty despite fuel in the tank
•Fluctuating fuel gauge readings while driving
•Fuel gauge needle stuck in one position
•Check engine light illuminated
•Inaccurate fuel level readings after refueling

Diagnostic Steps

1
Scan for any error codes using an OBD-II scanner to identify related issues.
2
Inspect the fuel tank sending unit for proper connection and signs of damage.
3
Check the wiring harness for continuity and damage between the sending unit and the gauge.
4
Measure the voltage at the fuel gauge to determine if it is receiving power.
5
Test the fuel sending unit resistance with a multimeter to ensure it is functioning correctly.
6
Verify the instrument cluster functionality by checking other gauges for proper operation.

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
•Screwdrivers
•Safety goggles
•Torque wrench

Parts Required

•Fuel sending unit (if faulty)
•Electrical connectors (if needed)

Related Faults

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Diagnostic Steps

1
Scan for any error codes using an OBD-II scanner to identify related issues.
2
Inspect the fuel tank sending unit for proper connection and signs of damage.
3
Check the wiring harness for continuity and damage between the sending unit and the gauge.
4
Measure the voltage at the fuel gauge to determine if it is receiving power.
5
Test the fuel sending unit resistance with a multimeter to ensure it is functioning correctly.
6
Verify the instrument cluster functionality by checking other gauges for proper operation.

Solution

1. Preparation

Gather all necessary tools and parts.
Disconnect the vehicle's battery to ensure safety during repairs.
Tools Required:
- OBD-II scanner
- Multimeter
- Socket set
- Screwdrivers
- Safety goggles
- Torque wrench

2. Access the Fuel Sending Unit

Lift the vehicle using a jack and secure it with jack stands.
Remove the fuel tank shield (if equipped) using a socket set.
Disconnect the fuel lines and electrical connectors from the fuel tank.
Carefully lower the fuel tank to access the sending unit.

3. Inspect and Test the Fuel Sending Unit

Remove the fuel sending unit from the tank according to the manufacturer's specifications.
Use a multimeter to measure the resistance of the sending unit. It should vary as you move the float arm.
- If resistance is not within the expected range, replace the sending unit.
Inspect the float for any cracks or damage that may prevent it from floating properly.

4. Check Wiring and Connections

Inspect the wiring harness for any signs of wear, damage, or corrosion.
Use a multimeter to check for continuity in the wiring between the sending unit and the gauge.
Repair or replace any damaged wiring or connectors.

5. Reassemble and Test

Reinstall the fuel sending unit and secure it according to specifications.
Reconnect the fuel lines, electrical connectors, and the fuel tank shield.
Raise the vehicle back to the ground, reconnect the battery, and start the vehicle.