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Bad fuel sending unit? Help please

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4.6K views 6 replies 6 participants last post by  mark0124  
#1 · (Edited)
Hey guys I just picked up an 02 F250 7.3 with 345k miles. The seller had a problem with the truck acting like it’s running out of fuel and losing power and replaced the following parts but none of this fixed it…

180/30 injectors, KC Turbo, Hydra Tuner, Jellibuilt tunes, cold air intake, 4” exhaust, mishimoto charge pipes, hoses, clamps, boots, ect. ECM, Fuel Pump, HPOP & lines, fuel lines, IPR, CPS, UVC wiring harness, ICP, LPOP, belt, alternator, coolant bottle.

When the truck is driven with a lot of fuel it drives great and has no problems. It starts acting up once when you get down to a quarter tank and the motor sounds like it’s running out of fuel and almost dies. I fill it back up and the problem goes away shortly. I unscrewed the fuel filter on the engine and heard a bunch of air come out. I put it back in and drove it around with low fuel and it did the same problem and the noise of air coming out happened again when I unscrewed it again. So air is getting in the fuel system somehow. My buddy has the same truck and his does the same thing and he thinks the problem is the fuel sending unit or it’s the after market additional fuel filter under the truck that he thinks could also be causing the problem. Has anyone experienced this and does anyone know the problem? The engine looks to be in great condition no blow by and runs strong. Again the problem is only when I’m at a quarter tank of fuel or less. Filled up half way or higher and it runs perfect. Thanks for any advice.
 
#2 ·
Read up on Hutch/ Harpoon Mod.

Hopefully you will come to understand it is called Fuel or Diesel.... Not Gas

The rest was just...
Image


And if any of those parts were not from the Ford or International counter guy... expect more and continued issues now and soon.
 
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#7 ·
I own a 94 f350 7.3 diesel. I've replaced 3 sending units since I've owned the truck. Same symptoms as you describe. My mechanic tells me the bottom 4" section of the sending unit does not do well in diesel. Hence it disintegrates or falls off. For now I use my rear tank as primary and switch to the front tank as reserve. As long as I keep fuel gauge above half I'm fine. As it gets toward 1/4 tank it starts running out of fuel. It's a shame Ford doesn't fix this problem or an aftermarket version overcomes this obvious defect.