Fuel level problem

Discussion in '2005+ Mustang GT 4.6L Tech' started by Fullboogie, Jun 4, 2013.

  1. Fullboogie

    Fullboogie King of the Geeks

    6,027
    406
    I recently replaced the fuel tank and pumps/hat in my 2007 GT500. The hat/pumps were from a 2011 GT500, but I swapped my original fuel level sender onto it (the wire colors matched up exactly between the two). Filled up the car and have been driving it this week.

    When I left for work this morning, the fuel gauge was on about 1/3 tank. On the way home, the low fuel level warning went off and told me I had 5 miles to empty. Round trip is 30 miles, so there's no way I used that much gas. So I'm thinking, OK, transfer tube is disconnected at either end, no big deal. If that's the case, I would have used only half the tank, right? That means filling the tank up should have taken somewhere around 7 gallons (1/2 tank).

    Pulled into the gas station and filled up, but it took 10.5 gallons. Does that rule out a transfer tube problem? If so, that leaves the sender, but how can that be screwed up? I pulled the hat up a few days ago and checked the arm, and it appeared to be in the proper place. Any ideas what would cause this???
     
  2. skwerl

    skwerl tree hugger

    15,399
    274
    I think you may be correct about the transfer tube.
     
  3. 05stroker

    05stroker Never enough power guy!

    13,010
    43
    This was my issue with the same problem. Pull the pump and check that damn tube. Your fill up sounds correct since part of the tank is above both sides. I would just pull both the pump hat and the pass side sensor and you will know for sure.
     
  4. Fullboogie

    Fullboogie King of the Geeks

    6,027
    406
    Then that would make sense - I didn't know that. And I can tell you that the whole time I was installing the fuel pump, I kept repeating to myself "make sure you connect both sides or you'll be doing this again."

    I double checked everything, so I have no idea how this could have happened. But I'll certainly check it real good. Thanks for the confirmation, guys.
     
  5. 05stroker

    05stroker Never enough power guy!

    13,010
    43
    Only takes 20 min to check it. Dont ask how I got so fast...
     
  6. Fullboogie

    Fullboogie King of the Geeks

    6,027
    406
    Oh, I know. I'm going to wait until I use up some of the gas. I topped it off on the way home, and I really don't feel like having my interior smell like gas for 2 weeks. Thanks again.
     
  7. 05stroker

    05stroker Never enough power guy!

    13,010
    43
    It will still smell like gas. You cant get around it. That shit smells! LOL
     
  8. crownaviation

    crownaviation http://www.tudyno.com/

    3,805
    1
    the siphon tube on the GT500 pump is a joke (the white down tube with the orange little hat that looks like a pencil eraser). It is connected via that lousy 3 prong plastic garbage. They do pop off easily when positioning it in the tank and same results as the transfer line not being connected. My guess is you had some fuel already burned out of the passenger tank when you installed the pump. You can fill it now but wont transfer any. That would explain why you were able to get that much fuel in on your first fill. The passenger side tank burns first.

    I would however check the black plastic PITA transfer line and make sure it is connected first tho. If it is then you likely had the siphon tube pop off.

    Mine did exactly what yours did and had same results. After first fill it would only burn half tank and then read 5 miles to empty. Yes.. it will run out of fuel too lol.. I found this out on a 1800 mile round trip with no way to fix it till I got home. Sucked.

    Oh,, get some band-aids ready lol. My favorite fuel pump word of the day.. "goddamfreakamutrfrkrfuck". It will lift your spirits some but you have to say it while grinding your teeth

    The plastic crossover line attaches to this. Usually why they come loose when you are fighting to connect the dang line.

    Other than these two things,, I am starting to hear about the black crossover lines cracking or getting kinked on installs. That would require replacing the line. Lets hope for option 1 or 2 tho (easy and does not require any parts usually)

    [​IMG]

    [​IMG]
     
    Last edited: Jun 5, 2013
  9. Fullboogie

    Fullboogie King of the Geeks

    6,027
    406
    I'll check the siphon tube too - it seemed to pop off rather easily when I had it on the bench. I just hate pulling the pump hat. If only the tank opening and the floorboard opening actually lined up, it wouldn't be that bad...
     
  10. S197gt07

    S197gt07 forum member

    4,063
    1
    You could loosen the straps holding the tank in and it'll line up better
     
  11. BruceH

    BruceH BBB Big Bore Boss 322

    13,802
    7
    I lay old towels and rags all around the hole and have plenty extras to sop up any unplanned spillage. I also have gallon zip lock bags ready to take any soiled rags. I hate the smell of gasoline and especially hate it inside my car. Spraying the area down with simple green after you are done will cut the smell and remove the residual.
     
  12. Paps

    Paps forum member

    665
    0
    ^^ this also happened to me. Ended by putting a wire all around. I saw a pic in parts for sale section and did the same. But i think my level problems (made 2 threads.....got 0 answers lol) came from my float. I swapped float assy with sender from my oem pump and problems solved!

    Edit found the pic: http://www.s197forum.com/forum/attachment.php?attachmentid=42187&d=1369181769
     
    Last edited: Jun 5, 2013
  13. crownaviation

    crownaviation http://www.tudyno.com/

    3,805
    1
    So you get it fixed or are you doing the 150 mile fill still? lol..

    Yes I think the tank thing was a sick joke by a disgruntled Ford engineer. Cheers to him cause he sure fucked a lot of people lol :rant:

    Forgot to mention that.. Look at the thread from papi above.. I do that with my pumps now and just use some small safety wire. Here is a pic he is referring to robbed from another OP..

    [​IMG]
     
    Last edited: Jun 10, 2013
  14. S197gt07

    S197gt07 forum member

    4,063
    1
    if the image was bigger than 56x100 it might be useful :crazy:
     
  15. crownaviation

    crownaviation http://www.tudyno.com/

    3,805
    1
    lol.. :stooges:

    actually was also in the link provided above by Paps. I circled his pic to highlight the area

    [​IMG]
     
    Last edited: Jun 11, 2013
  16. Fullboogie

    Fullboogie King of the Geeks

    6,027
    406
    I've been at a jetski race for the last 5 days, so I haven't run much gas out of the tank yet. Hopefully I will get to it this weekend. Thanks for keeping this on the radar.
     
  17. icebox

    icebox forum member

    70
    0
    has anybody ever changed that transfer tube ? it looks like a pain the rear !
     
  18. Fullboogie

    Fullboogie King of the Geeks

    6,027
    406
    If you're talking about the one that goes from one side to the other, it wouldn't be hard to do. The tube is held in place by a friction clip right about in the middle of the tank, so you have to reach in there and unsnap it. Otherwise, it just lifts out.

    On the way to work this morning, I reached just a smidge above 1/2 tank, so I ought to get the buzzer on the way home. I'll tackle this Saturday morning and post a pic of what I found. Really looking forward to the interior smelling like gas for 4 days again...
     
  19. Fullboogie

    Fullboogie King of the Geeks

    6,027
    406
    Quick update - it was, indeed, the crossover tube that had popped off of the driver's side. Given what a bitch it is to remove the thing in the first place, I can't imagine how it pops off during the re-installation process. Easy fix, though.
     
  20. crownaviation

    crownaviation http://www.tudyno.com/

    3,805
    1
    They are actually a bastard to get on too sometimes. Glad it was a simple fix, minus the quart of blood you likely spilled