I want to see if anyone on here has an idea what the issue may be with my truck. It is a 2002 XTL 4.0 V6. My entire "Fuel Pump Module Assembly" was replaced about 18 months ago because it was determined that a sensor in the sending unit was bad and the truck wouldn't pass inspection. The symptoms were a fuel gauge pinned to full and the check engine light on with a code reading "P0460 Fuel Level Sensor Circuit".

Now here I am with the same exact issue. Fuel gauge pinned to full and the same error code. Is it possible the sensor went bad already? Could my mechanic have messed something up? Any thoughts and ideas are much appreciated. Thanks!

 

Yes, its possible, was the fuel pump assembly replaced with Motorcraft brand?

The fuel level system uses these OHMs
16 OHMs Empty
160 OHMs Full

OHMs are resistance
0 OHMs is a dead short, no resistance
1 million OHMs is an open circuit, i.e. no connection

So fuel gauge needle at full(160 ohms or higher) can be a broken wire
And since you are getting P0460 the wire would have to be broken between gas tank and computer, so not an instrument cluster issue

The Yellow/white stripe wire at the gas tank is the sender wire, and there is also a Black/orange ground wire for the sender there as well, if EITHER wire was broken/disconnected then gauge would show FULL and you would also get P0460

So it may not have been a sender issue last time, it may be connector on the tank issue or wire issue that has come back