what causes the fuel gauge to malfunction in my Ford Mustang S650 (2024-Present)?

Solution

1. Preparation

• Gather necessary tools and parts.
• Disconnect the vehicle's battery to ensure safety.
• Ensure the fuel tank is at a manageable level for safe work.

2. Inspect Fuel Sending Unit

• Remove the rear seat or access panel to locate the fuel pump assembly.
• Disconnect the wiring harness from the fuel sending unit.
• Remove the fuel sending unit from the tank (follow manufacturer specifications for torque).
• Inspect the float mechanism for damage and ensure it moves freely.
• Clean any debris from the fuel tank and sending unit area.

3. Test and Replace Components

• Use a multimeter to check the resistance of the fuel level sensor. Compare readings to manufacturer specifications.
• If readings are outside specifications, replace the fuel sending unit.
• Reassemble the fuel sending unit and reconnect the wiring harness.

4. Instrument Cluster Inspection

• Remove the instrument cluster (follow manufacturer specifications for removal).
• Inspect for any visible damage to the circuit board or connectors.
• If necessary, replace the instrument cluster.

5. Reassembly and Final Checks

• Reconnect the vehicle's battery.
• Reinstall any panels or seats that were removed.
• Start the vehicle and check the fuel gauge operation.