how to fix the fuel gauge not working in Ford F-150 13th Generation (2015-2020)

Ford F-150 13th Generation (2015-2020)

Error Codes

2-4 hours

Time

medium

Difficulty

medium

Severity

3 min read

541 words

Problem Statement

Learn how to diagnose and fix the fuel gauge issue in Ford F-150 (2015-2020). 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 the fuel system.
•Allow the engine to cool completely before starting repairs to avoid burns.

Symptoms

•Fuel gauge shows empty despite fuel in the tank
•Fuel gauge fluctuates erratically
•Check engine light illuminated
•Fuel level warning light remains on
•No movement in the fuel gauge needle when ignition is turned on

Diagnostic Steps

1
Scan the vehicle's OBD-II system using a scanner to check for error codes related to the fuel system.
2
Inspect the fuel level sensor located in the fuel tank for any visible damage or disconnections.
3
Check the fuel gauge wiring harness for any signs of corrosion, wear, or disconnection.
4
Test the fuel sender unit's resistance using a multimeter to ensure it is functioning within specifications.
5
Verify the operation of the instrument cluster by accessing the self-test mode (if applicable) to ensure the fuel gauge is operational.
6
Inspect the fuel pump relay and fuses associated with the fuel system for any faults.

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
•Screwdriver set
•Fuel line disconnect tool

Parts Required

•New fuel level sensor
•Fuel pump assembly (if necessary)

Related Faults

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Diagnostic Steps

1
Scan the vehicle's OBD-II system using a scanner to check for error codes related to the fuel system.
2
Inspect the fuel level sensor located in the fuel tank for any visible damage or disconnections.
3
Check the fuel gauge wiring harness for any signs of corrosion, wear, or disconnection.
4
Test the fuel sender unit's resistance using a multimeter to ensure it is functioning within specifications.
5
Verify the operation of the instrument cluster by accessing the self-test mode (if applicable) to ensure the fuel gauge is operational.
6
Inspect the fuel pump relay and fuses associated with the fuel system for any faults.

Solution

1. Preparation

Gather tools and parts needed for the repair.
Tools Required: OBD-II scanner, multimeter, socket set, screwdriver set, fuel line disconnect tool.
Ensure safety by disconnecting the battery and relieving fuel system pressure before beginning work.

2. Remove Fuel Tank

Sub-steps:
1. Raise the vehicle using a jack and secure it with jack stands.
2. Remove the skid plate, if equipped, by unscrewing the bolts.
3. Disconnect the fuel filler neck and any attached hoses.
4. Support the fuel tank with a jack and remove the mounting straps.
5. Carefully lower the fuel tank to access the fuel pump and sender unit.

3. Replace Fuel Level Sensor

Sub-steps:
1. Disconnect the wiring harness from the fuel level sensor.
2. Remove the fuel pump assembly from the tank.
3. Detach the fuel level sensor from the assembly.
4. Install the new fuel level sensor and reassemble the fuel pump assembly.
5. Reinstall the fuel pump assembly back into the fuel tank.

4. Reinstall Fuel Tank

Sub-steps:
1. Lift the fuel tank back into position, ensuring no hoses are pinched.
2. Secure the tank with the mounting straps and reconnect the fuel filler neck.
3. Reattach any hoses and the skid plate (if removed).
4. Reconnect the battery.