I changed my Sending Unit, pumped the tank dry, poured the fuel back, with a Surprise! 
I finally broke down and bit-the-bullet and payed the Ridiculous price for a sending unit and here's what I found. First I had @350mi on the last fill-up when I drained the tank and found 11gallons remaining. After replacing the tank I added the fuel back, 5gals at a time, and was surprised to find how the gauge read what went back in.
0-6gals - Low Fuel Warning was ON.
+5gal - gauge reads 1/8th of a tank (11TL)
+5gal - gauge reads 1/4 (a bit over) (16TL)
+5gal - gauge reads 3/8ths (just over) (21TL)
+5gal - gauge reads 1/2 (again, just over) (26TL)
At this point, no more cans, I drive to the station and it takes 17 to fill (Harpoon Mod makes it 42gal tank I guess, I'm deducting 1gal for the 12mi I drove it)
I would have NEVER Imagined, when down to 1/8 of a tank I had So Much fuel left! I guess I was thinking of it Wrong, at "E" the 5-6gal reserve isn't in the picture at all so, as far as the PCM is concerned, 1/2 tank is 21gallons.
A few years back, when I did the Hutch & Harpoon, I drove about 10mi home after the Low Fuel light came on. When I pumped the tank dry it filled a 5gal can, so I Knew that and is why I initially put 5, then an additional 1 in attempt to get the light off. I would add the fuel, restart, drive around the block once, and cycle the key to take the reading between cans. Because the PCM gives a computed average reading (or every corner/hill/brake/acceleration doesn't whip the needle around) I wanted to give it a chance to decide where the needle belonged.
But I have to tell ya,,, before this, if I was driving on the HiWay with an 1/8th of a tank and saw a sign that said "Next Fuel Stop 125mi" I would have been Real Concerned!:wink[3]:
btw: it's an '02 F350 - Reg cab - 8ft bed - 137" WB ~ What the OM calls "Long Box" 38gal tank
I finally broke down and bit-the-bullet and payed the Ridiculous price for a sending unit and here's what I found. First I had @350mi on the last fill-up when I drained the tank and found 11gallons remaining. After replacing the tank I added the fuel back, 5gals at a time, and was surprised to find how the gauge read what went back in.
0-6gals - Low Fuel Warning was ON.
+5gal - gauge reads 1/8th of a tank (11TL)
+5gal - gauge reads 1/4 (a bit over) (16TL)
+5gal - gauge reads 3/8ths (just over) (21TL)
+5gal - gauge reads 1/2 (again, just over) (26TL)
At this point, no more cans, I drive to the station and it takes 17 to fill (Harpoon Mod makes it 42gal tank I guess, I'm deducting 1gal for the 12mi I drove it)
I would have NEVER Imagined, when down to 1/8 of a tank I had So Much fuel left! I guess I was thinking of it Wrong, at "E" the 5-6gal reserve isn't in the picture at all so, as far as the PCM is concerned, 1/2 tank is 21gallons.
A few years back, when I did the Hutch & Harpoon, I drove about 10mi home after the Low Fuel light came on. When I pumped the tank dry it filled a 5gal can, so I Knew that and is why I initially put 5, then an additional 1 in attempt to get the light off. I would add the fuel, restart, drive around the block once, and cycle the key to take the reading between cans. Because the PCM gives a computed average reading (or every corner/hill/brake/acceleration doesn't whip the needle around) I wanted to give it a chance to decide where the needle belonged.
But I have to tell ya,,, before this, if I was driving on the HiWay with an 1/8th of a tank and saw a sign that said "Next Fuel Stop 125mi" I would have been Real Concerned!:wink[3]:
btw: it's an '02 F350 - Reg cab - 8ft bed - 137" WB ~ What the OM calls "Long Box" 38gal tank