Five Hundred AWD V6-3.0L VIN 1 (2005)
Fuel Gauge Sender: Customer Interest
Instruments - Inaccurate Fuel Gauge/Mil ON/DTC's Set
TSB 06-17-2
09/04/06
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.
