truck-1996 2500 extra cab long bed 250k-ish miles, one owner

my truck runs out of duel after about half a tank,, i am guessing that tube inside the fuel reservoir insert thing is broken. the sending unit and float are probably toast as well since my fuel guage barely works, mostly says empty

this truck is still in good shape but i am worried about throwing too much in parts at it,, but the only replacement part i can find is a carter replacement for like 180 bucks!
anyone done this recently,, where did you find your part?

thanks, kevin

 

I haven't had to replace the module, but if I did then this is the one: https://www.genosgarage.com/product/...ank-components

It's more than you paid, but it is at least the part number I would go for. I have heard of some people buying the tank module on Amazon (and/or elsewhere, perhaps) and getting one for a later gasser that has an in-tank fuel pump. They had a heck of a time figuring out the problem caused by trying to draw fuel through a non-operable electric pump in the module!

I have heard of the draw tub in the module cracking and causing symptoms like yours. The gauge sending unit may be repairable - I have read on another forum about putting a nylon washer in the pivot to take up clearance and restore contact. You may be able to find posts on that with the search feature, or with google. I know the forum I saw it on, but it's probably a forum-rules violation to openly publish a link here to a competing forum. If I can find it, I'll try to find it and PM it to you if you don't find it first. But it may take a while as my truck is currently down and demanding much attention.

 

thanks tex! i actually saw a similiar thread about fixing the potentiometer and contacts,,,or i saw a you tube video on it. but i looked at genos and it is just the rebranded carter that i bought. i decided to just bite the bullet and get new one. i don't want something else breaking on the old one and getting me stranded somewhere.
anyway,, waiting for it to arrive.

ironically,, i bought a "used like new" 2019 f350 6.7 cclb 4x4 after i got this truck and it is spoiling me. except for typical ford steering components,,,,,,,, REALLY FORD???? 20 YEARS OF THE SAME PROBLEM AND YOU STILL CAN'T FIX IT???

 

I saw that you posted on "the other forum" I referred to above - you got some good replies there, so I didn't respond as I didn't have anything to add on that thread. I understand your reasoning for going ahead and getting the new module (I've used that reasoning myself at times) - just verify that it is the diesel model (no electric fuel pump inside the module).

 

I spent several years dealing with this "half tank" issue. So far, it's gone, as it took me about a decade to finally figure out what it was.

Thread here.Air in fuel issue

I put photos of where the issue actually occurs in my 1st gen. I'm not sure if the 2nd gen reservoir is the same as my first gen, but it's worth the read to see how I fixed it (IMO).

I consistently run my tank down to near empty and I've been without the issue of sitting on the side of the road. The seals go bad in the reservoir, and it's a bit complicated to get to them, which is why I never originally attempted to do this in the first place. When I finally got the old seals out, they were shot. They didn't sit tight on the brass pickup tube, and depending on circumstance would allow air in the tank to enter the lines.