2004-2007 Ford Explorer MIL ON WITH DTC P0463 OR ERRATIC FUEL GAUGE OPERATION SERVICE PROCEDURE

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ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. For vehicles with customer symptom of erratic fuel gauge operation (with no MIL on), proceed to Step 1a. For vehicles with a customer symptom including the MIL on, proceed to Step 1b. If unable to verify the concern, do not continue with this TSB. a. Follow the appropriate pinpoint test (PPT) for “Fuel Gauge Inaccurate” in Workshop Manual (WSM), Section 413-01. If PPT test results lead to fuel pump module replacement, proceed to Step 2. If PPT test results isolate any problem other than fuel pump module replacement, repair as indicated and do not continue with this TSB. b. Install diagnostic scan tool to retrieve DTCs. If DTC P0463 is retrieved, proceed to Step 2. If DTC P0463 is not retrieved, this TSB does not apply, follow normal WSM diagnostics. 2. Remove fuel tank per WSM, Section 310-01 3. Remove fuel pump assembly from fuel tank per WSM, Section 310-01. See Figure 1 (Chart) to determine if a kit (contains a fuel level sensor assembly, a wire harness and heat shrink tube) or fuel pump assembly is required for repair. For vehicles that can be serviced with a kit go to Step 4. For vehicles that require fuel pump assembly replacement, go to Step 12. 4. Remove the fuel level sensor assembly (sender card/float rod assembly) from the fuel pump assembly per WSM, Section 310-01