Instruments - Inaccurate Fuel Gauge/Mil ON/DTC's Set
TSB 06-17-209/04/06
FUEL GAUGE ERRATIC/INACCURATE AND/OR MIL
ON WITH DTC P0463, B1202, B2627, B2879, AND/OR
P2068
FORD:
2005-2007 Five Hundred, Freestyle
MERCURY:
2005-2007 Montego
ISSUE
Some 2005-2007 Freestyle, Five Hundred, and Montego vehicles may exhibit a fuel gauge that is inoperative (reads empty with fuel in the tank), reads less than full when full, is slow to respond after fill, or is erratic/inaccurate. The vehicle may also exhibit the malfunction indicator lamp (MIL) on with diagnostic trouble code (DTC) P0463, B1202, B2627, B2879, and/or P2068. This may be due to fuels which contain high amounts of sulfur which can react with electrical contact surfaces and cause an unwanted increase in electrical resistance.
ACTION
Install new sender card/float rod assemblies with a redundant ground/swipe for both sides of tank. The components in this kit are significantly more tolerant of exposure to high sulfur fuels. On Freestyle only, the primary side (passenger side) also has a longer float rod arm to improve fuel gauge accuracy. Follow the Service Procedure steps to correct the condition.
Do not perform this TSB for DTC P0460. DTC P0460 is set when the vehicle is driven approximately 120 miles (193 km) if the fuel gauge indication has not dropped more than 3% in that time. DTC P0460 is primarily set by two (2) refueling habits: 1) Multiple refuelings with relatively small amounts of fuel; 2) Refueling beyond the nozzle automatic shut off level. To prevent P0460 due to refueling habits, it is recommended that a minimum of 5 gallons is purchased and allowing no more than two (2) automatic pump click-offs.
SERVICE PROCEDURE
1. Remove Fuel Pump Module and Fuel Level Sensor following instructions in Workshop Manual (WSM), Section 310-01.
CAUTION
THE FUEL TANK LEVEL SHOULD BE 7/8 OR LESS PRIOR TO FUEL PUMP SENDER SERVICE THROUGH THE FLOOR PAN ACCESS HOLE.
2. Update both with the parts from the kit referring to the following tips.
CAUTION
WHILE THE FUEL MODULES ARE OUT OF THE TANK, FUEL VAPORS WILL BE PRESENT, CARE SHOULD BE TAKEN TO MAKE SURE SMOKING/WELDING/GRINDING ETC ARE NOT BEING PERFORMED IN THE SAME PROXIMITY AND OTHERS ARE AWARE OF THE OPEN FUEL SYSTEM.
a. The parts in the kits look similar so check the part number printed on the part to ensure it is being installed in the correct location. Refer to the following list:
^ 5F93-9A299-CA: Freestyle - Primary side (Passenger side)
^ 5F93-9A299-DA: Freestyle - Secondary side (Driver side)
^ 5G13-9A299-EA: Five Hundred/Montego - Primary side (Passenger side)
^ 5G13-9A299-FA: Five Hundred/Montego - Secondary side (Driver side)
NOTE
THE NEW CARD AND FLOAT ROD ASSEMBLIES FOR THE PRIMARY SIDE (PASSENGER SIDE) HAVE FLOATS WHICH SPIN AROUND ON THE FLOAT ROD. NEW CARD AND FLOAT ROD ASSEMBLIES FOR THE SECONDARY SIDE (DRIVER SIDE) HAVE FLOATS FIXED TIGHTLY TO THE FLOAT ROD.
CAUTION
CARE SHOULD BE TAKEN TO COMPLETELY DRAIN THE FUEL MODULES AND DRY THE MODULES PRIOR TO THE BENCH UPDATE TO PREVENT THE HEATING PROCESS FROM BEING AN IGNITION HAZARD.
b. To install the sender card/float rod assemblies on the current Fuel Pump Module and Fuel Level Sensor Assembly, first remove the screw from the bottom of the component which attaches a metal backing plate. Once the bottom is loose, the plate should rotate up and disconnect from the module. Carefully cut the shrink wrap from the yellow wire, then disconnect the electrical terminal by depressing the release tab and pulling it apart.
c. Install the sender card/float rod assemblies in a similar fashion as the original ones, except two (2) eyelets (old ground wire and new pink wire) will now fit under the screw instead of one (1). Slide the supplied new shrink wrap tube over the yellow wire and connect the electrical terminal. Apply heat to the shrink wrap over the terminal so it shrinks tightly around the terminals.
d. Route the wires in a similar fashion as when removed, and run the float through its travel to confirm the wires will not contact the float rod.
3. Reinstall per WSM procedure.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
061702A 2005-2007 Five Hundred, 1.8 Hrs.
Montego: Check Diagnostic
Trouble Codes And Install
New Sender Cards For
Both Sides Of Fuel Tank
(Do Not Use With 9002A,
9275A, 12650D)
061702B 2005-2007 Freestyle: 2.1 Hrs.
Check Diagnostic Trouble
Codes And Install New
Sender Cards For Both
Sides Of Fuel Tank (Do
Not Use With 9002A,
9275A, 12650D)
DEALER CODING
CONDITION
BASIC PART NO. CODE
9275 42
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