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Discussion Starter · #1 ·
I purchased a 2005 XLT 6 days ago. Has 172k miles. Runs great, have an edge insight CTS2 on it and no codes when I bought it.

3 days ago, I started it up in the morning and fuel gauge was buried below E and center display said low fuel. I had filled it the day before and had only driven it about 50 miles so I know it had plenty of fuel. A couple minutes later the message went away and the needle popped back up. It's done this a few times now, even while driving (not just at start up). When its on and working, it's always reading accurately.

Last night, driving home, the fuel issue occurred and when I looked down, the speedo needle was pointing straight down. A couple minutes later the fuel gauge started working again, but speedo did not. When I got off the freeway, I noticed the speedo was moving in relation to my speed, just WAY off. When I came to a stop, it was sitting at 55. As of today (two more drives since last night), the speedo is still way off. Although, this morning when stopped, it's now sitting at about 45.

Everything else works fine. No issue with power to radio or windows, all other gauges work fine, etc. No engine check light, but when I checked codes this morning with the edge insight, it did show P0460 and P0463.

One note, the day before the first time I saw an issue with the fuel gauge, I had changed batteries. I had both batteries disconnected for 20 minutes or so. I have no idea if this could have anything to do with this, just thought I would mention it. I've only had the truck 6 days so don't really have any history with it to know if it had any such issues before buying it. Maybe there is some procedure to reconnecting batteries or something?

Any help would be greatly appreciated!! Don't want to start pulling sending unit or shipping cluster out for repair if I can avoid it without knowing for sure the cause.

TIA!
 

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probably need a trip to the cluster shop

my speedo did the same it was the stepper motor i drilled a tiny hole in the lens and reset it to 0

three years later I just replaced the lens it has never given me issues since i reset it LOL


there is a guage sweep trick you can google and see if they sweep proper
 

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135 Posts
Discussion Starter · #5 ·
Thanks for the tip about gauge sweeps! I found the below info and I went and tried it. Sweeping the gauges fixed the speedometer issue and it's back to correct place. Still concerned about why it did it in the first place and wonder if it will happen again.

Also still need to figure out the fuel gauge issue. Hope it's not a bad sending unit.

http://www.powerstroke.org/forum/6-...sion/153117-test-gauges-factory-mod-help.html
To enter the HEC Dealer test mode, depress and hold the instrument cluster SELECT/RESET button, turn the ignition switch to the RUN position, and then continue pressing the SELECT/RESET button (5 seconds) until tESt is displayed in the odometer. The SELECT/RESET button must be released within 3 seconds of the odometer tESt display to begin the dealer test mode.

Depress the SELECT/RESET button to advance through the following steps until dtc is displayed. Depressing the SELECT/RESET button will display any stored continuous DTCs before proceeding to the next step.

Odometer Display Description

GAGE
Activates gauge sweep of all gauges, then displays present gauge values. Also carries out the checksum tests on ROM and EE. If the gauge sweep is inoperative, INSTALL a new instrument cluster.

All segments illuminated
Illuminates all odometer segments. If any odometer segment is inoperative INSTALL a new instrument cluster.

bulb
Illuminates all micro-controlled indicators and LEDs. Install a new indicator or LED as necessary.

r
Returns to normal operation of all micro-controlled indicators and LEDs and displays hexadecimal value for ROM level. (used when requesting assistance from the hotline). If alternating flashes for FAIL and ROM level are displayed, INSTALL a new instrument cluster.

EE
Displays the hexadecimal value for EE level (used when requesting assistance from hotline). If alternating flashes of FAIL and EE level are displayed replace instrument cluster.

dt
Displays hexadecimal coding of final manufacturing test date (used when requesting assistance from hotline).

dtc
Displays continuous DTC's in hexadecimal format. Pressing the SELECT/RESET button will display any DTCs stored before proceeding to the next step.

enG
Displays the English speed in MPH. Speedometer will indicate present speed within tolerances. Display will show 0 if input in not received. If input is invalid for one second or more, or if speed is 0.

m
Displays the metric speed data in kph. Speedometer will indicate present speed within tolerances. Display will show 0 if input in not received. If input is invalid for one second or more, or if speed is 0.

tAc
Displays the tachometer data received from the PCM via the SCP network within tolerances. Tachometer will indicate present RPM. Display will show 0 if input is no received, if input received is invalid for one second or more, or if engine RPM is 0.

FUEL
Displays the code (0-255) for the fuel sender input to the HEC. The fuel gauge will display a filtered fuel level value. This filter will keep the pointer from moving suddenly or erratically.
255 open send +/- 0
232 full stop +/- 0
215 Full mark +/- 10
178 3/4 mark +/- 8
138 1/2 mark +/- 7
93 1/4 mark +/- 5
41 E mark +/- 4
54 Low Fuel (0-59)
0-18 short (0-20 max)

OIL
Displays the code (0-250) for the oil pressure switch input to the HEC. Oil pressure gauge will indicate present oil pressure. Normal oil pressure (greater than 6psi) will display a value between 000 and 176. A low oil pressure or an inoperative engine oil pressure switch (less than 6 psi) will display a value greater than 176.

dEGC
Display of engine temperature in Degrees C input from cylinder head temperature sensor.
49 C "C" mark
60 C Normal band start
120 C Normal band end
-40 C No SCP message for 5 seconds

bAtt
Displays the code (0-255) for the battery voltage input to the HEC. Battery voltage gauge will indicate present battery voltage. 93-102 6.2-9.1 volts, low voltage
115-124 8.5-10.7 volts, Normal band start
215-225 15.8-18 volts, Norm band end
230-241 16.9-19.1 volts, high voltage

rhEo
Displays the present decimal rheostat dimming input, 0-255 (used when requesting assistance from the hotline)

rhi Not used.
rhS Not used.
rho Not used.

Cr
Displays the current RUN/START sense input. Display will show -h for high input with the ignition switch in the START position and -L for low input with the ignition switch in the RUN position.

PA-PE7 not used.

GAGE Repeats the display cycle
 

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My 06 started doing the fuel gage thing about 6 mo out of warrant, dealer wanted $475 for
parts and $450 for labor. I drove it another 5 years and it worked most of the time. I got a
new Ford sending unit from Rock Auto.com, put it in and and all is well now.
I think the new sending unit from them cost around $275. Good luck.

Doug
 

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135 Posts
Discussion Starter · #7 ·
My 06 started doing the fuel gage thing about 6 mo out of warrant, dealer wanted $475 for
parts and $450 for labor. I drove it another 5 years and it worked most of the time. I got a
new Ford sending unit from Rock Auto.com, put it in and and all is well now.
I think the new sending unit from them cost around $275. Good luck.

Doug
Yeah, if it doesn't hurt anything, I think it will be awhile before I fix it. I found a few sending units for $200 online, and a good video from the late Diesel Tech Ron on how to change it without dropping the tank. So next summer might tackle it.
 
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