Fuel level issue - Ford Powerstroke Diesel Forum
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post #1 of 5 Old 10-10-2013, 02:04 PM Thread Starter
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Fuel level issue

I have an '02 with 200,000 miles. It runs out of fuel when the gauge shows only 3/8 of a tank. Filling the tank, it only takes about 21 gallons so I know I still have quite alot of fuel. I pulled the tank thinking I had a problem with the pickup (again), but it is intact. Could I have a problem with the calibration of the gauge or fuel pump, or can I adjust the float? Any other solutions come to mind from anyone. Also, what is a "hutch" mod? Thanks for your help.
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post #2 of 5 Old 10-10-2013, 04:32 PM
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Look carefully for a crack that would allow air to be sucked in the mixer and pick-up. That really does sound like your problem, it's not at all uncommon...

Here's the Hutch page -> Welcome to guzzle's In-tank Hutch Mod Web Page
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post #3 of 5 Old 10-10-2013, 04:40 PM Thread Starter
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i thought of this and will check that in the morning. Thanks for your input.
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post #4 of 5 Old 10-11-2013, 11:34 AM Thread Starter
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Found the problem

My fuel pickup was ok. No cracks. It turns out the fuel check valve is bad. It's a small bladder type vavle on the side of the mixing chamber and it is allowing air into the fuel supply when the fuel level gets below it. Ford has wisely discontinued this $5 part in favor of a whole new $500 pickup assembly. My solution is to attach a 6" length of fuel line in it's place and extend it below the level of the sump, thereby assuring that it is always "underwater" and not able to leak air. It also looks like the hutch mod would solve this problem but that looks like a lot more work. Thanks for the input.
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post #5 of 5 Old 10-12-2013, 11:58 AM
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Quote:
Originally Posted by pbs210 View Post
My fuel pickup was ok. No cracks. It turns out the fuel check valve is bad. It's a small bladder type vavle on the side of the mixing chamber and it is allowing air into the fuel supply when the fuel level gets below it. Ford has wisely discontinued this $5 part in favor of a whole new $500 pickup assembly. My solution is to attach a 6" length of fuel line in it's place and extend it below the level of the sump, thereby assuring that it is always "underwater" and not able to leak air. It also looks like the hutch mod would solve this problem but that looks like a lot more work. Thanks for the input.
Hutch mod is not hard at all and can be done for cheap. If you have to drop the tank anyways, you may as well do it once, do it right(by doing the hutch mod), be done and never think about it again

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