Ameer Randolph
Ford's dual fuel tank system is a convenient feature that allows drivers to switch between two separate fuel tanks, extending their driving range before needing to refuel. This system is particularly useful for larger vehicles like trucks and SUVs, where the dual tanks provide a combined fuel capacity greater than a single, larger tank could offer. The dual fuel tank system operates independently and automatically, with fuel transferring from the rear tank to the front tank when the front tank's fuel level drops below three-quarters full. While this system is generally reliable, proper maintenance is crucial, as issues with fuel pumps, selector valves, or fuel gauges can lead to unexpected fuel shortages. Understanding how the dual fuel tanks work and how to manage them effectively is essential for any Ford owner to get the most out of their vehicle.
| Characteristics | Values |
|---|---|
| How does the fuel transfer between tanks work? | When the fuel level in the front tank drops below three-quarters full, fuel automatically transfers from the rear tank to the front tank. |
| How does the gauge switching work? | The switch on the dash only switches the gauge to which sender in the tank. The actual switch for the gas to be pulled from either tank is manual and on the floor behind the driver's seat. |
| How does the fuel pressure work? | When a tank is selected, the fuel pressure moves a valve to allow fuel to flow from that tank and block the ports to and from the other tank. |
| How does the fuel gauge sender work? | The fuel sender consists of a variable screened resistor made up of a ceramic substrate. It is controlled by the action of an attached float in the fuel tank. When the fuel level is low, resistance in the sender is low, and when the fuel level is high, the resistance in the sender is high. |
| How much gas can the tanks hold? | The amount of gas that can be held in the tanks varies. For example, a '71 model can hold 7 gallons in the front auxiliary tank and 11 gallons in the rear main. |
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What You'll Learn
Fuel tank selector solenoid
The fuel tank selector solenoid is a component of a vehicle's fuel system, specifically in vehicles with dual fuel tanks. It plays a crucial role in allowing the driver to choose between the two fuel tanks. When a tank is selected, the solenoid activates a mechanism that moves a valve, enabling fuel to flow from the selected tank while blocking the ports to and from the other tank. This ensures that fuel is drawn from the desired source.
In some Ford vehicles with dual fuel tanks, such as the 1988 model mentioned in a forum, the fuel tank selector solenoid is part of the fuel system. This particular system includes a pump in both tanks, an inline pump, and a low-pressure pump and sending unit in each tank. The selector solenoid is likely utilised to control the flow of fuel between the tanks and the engine, allowing for a seamless transition between fuel sources.
The fuel tank selector solenoid is an essential component for vehicles with dual fuel tanks, as it provides the ability to choose between tanks and ensures the proper routing of fuel. It is designed to be durable and function correctly for an extended period. However, in some cases, issues may arise, such as the solenoid becoming stuck or malfunctioning, requiring troubleshooting and potential replacement.
As per the reviews, the fuel tank selector solenoid is generally easy to install and functions as expected. It is a crucial component for controlling fuel flow in vehicles with dual fuel tanks. The solenoid, along with the selector valve, ensures that fuel is drawn from the selected tank while isolating the other. This mechanism is an integral part of the dual fuel tank system, providing drivers with the flexibility to utilise multiple fuel sources.
In conclusion, the fuel tank selector solenoid is a vital component in the dual fuel tank systems of certain Ford vehicles. It enables drivers to choose between fuel tanks and ensures the proper routing of fuel. While generally reliable and durable, regular maintenance and attention to the solenoid's functionality are important to ensure uninterrupted vehicle performance.
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Fuel gauge sender
The fuel gauge sender is a crucial component in a Ford dual-fuel tank system, providing information about the fuel level in each tank. It consists of a variable screened resistor made of a ceramic substrate and is controlled by a float attached to it within the fuel tank. As the fuel level fluctuates, the float moves accordingly, resulting in varying resistance levels in the sender. When the fuel level is low, the sender exhibits low resistance, while high fuel levels correspond to high resistance. This resistance gradually and continuously increases as the float moves from empty to full.
The proper functioning of the fuel gauge sender is essential for accurate fuel level readings. If the gauge only reads full, it could indicate an issue with the sender's lead wire or a lack of proper grounding. In such cases, troubleshooting steps, such as performing a continuity test on the fuel sender wire, can help identify the root cause. If the gauge still fails to function, the problem may lie with the sending unit, requiring further inspection and potential replacement.
Additionally, the correct installation of the float arm plays a significant role in the fuel gauge sender's accuracy. If the float arm is installed on the wrong side or the rheostat is upside down, the gauge will read backward. It's important to ensure that the bracket is in full contact with the flange and that there is full continuity between the metal strip connecting the rheostat and the bracket to the flange.
To ensure the fuel gauge sender operates correctly, it's crucial to match the resistance of the sender to that of the gauge. For example, the stock gauge in a 55 Chevy has zero ohms when empty and 30 ohms when full. By understanding the relationship between the sender's resistance and the gauge's readings, potential issues with the sender or wiring can be identified and addressed.
In some cases, issues with the fuel gauge sender may be related to the wiring or tank switch. To diagnose this, you can perform a simple test by unplugging the two-wire connector from the tank and grounding the wire from the front of the truck. If the gauge responds as expected, the wiring and switch are functioning correctly. However, if there is no movement on the gauge, the problem likely lies with the wiring or the tank switch, requiring further inspection and cleaning of the wire connector, terminals, and grounding point. If issues persist, it may be necessary to drop the tank and address the sending unit.
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Fuel return line
In some dual-fuel tank setups, the return line constantly fills the same tank. This approach is straightforward, but it requires careful monitoring to avoid overflow. To address this issue, some vehicles employ a solenoid or switching valve that diverts the return line to the tank being drawn from, ensuring a more balanced fuel level between the two tanks. This method, however, requires additional components and wiring, increasing the complexity of the system.
Another consideration for the fuel return line is the type of valve used. Some systems utilise a simple single-wire valve, while others employ a more expensive six-port valve. The choice of valve depends on factors such as cost and the specific requirements of the fuel supply volume. Additionally, the inclusion of a theft deterrent feature, such as a "Dead Man Switch," can influence the design of the return line and valve setup.
The Ford dual-fuel tank system incorporates a selector valve that simultaneously switches both the supply and return lines. This design allows for efficient fuel management and ensures the proper functioning of the engine. By referring to Ford's piping and wiring diagrams, vehicle owners can gain a comprehensive understanding of this system and its implementation. Furthermore, the availability of aftermarket parts, such as the Pollak tank selector valve, offers additional options for customisation and optimisation of the fuel return line setup.
In summary, the fuel return line in a dual-fuel tank setup plays a crucial role in maintaining appropriate fuel levels and preventing overflow. The specific configuration of the return line can vary, depending on factors such as vehicle type, fuel system design, and personal preferences. By consulting forums, vehicle-specific resources, and considering the experiences of other vehicle owners, one can make informed decisions about the setup and optimisation of the fuel return line in their dual-fuel tank system.
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Fuel pump failure
Low fuel pressure may also indicate a failing fuel pump. You can use a fuel pressure gauge to measure the pressure in the fuel system. If the pressure is low, it could be due to a faulty pump. When you turn the key to the "on" position without starting the engine, you should normally hear the fuel pump prime. If you don't hear this, it could be a sign that the pump is faulty.
In some cases, a malfunctioning fuel pump relay can also cause fuel delivery issues, leading to similar symptoms as a failing fuel pump. It's important to inspect the fuel pump relay as part of the diagnostic process to identify the root cause of the problem.
To address fuel pump failure, you may need to replace the pump. This involves accessing the fuel pump, which can vary depending on your Ford model, as you may need to access it through the trunk, under the rear seat, or by dropping the fuel tank. Once accessed, carefully disconnect the electrical connectors and fuel lines before installing a new, compatible unit. It is important to follow the manufacturer's instructions and safety protocols during this process.
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Fuel transfer process
The fuel transfer process in a dual-tank system varies depending on the vehicle's make, model, and year. Here is a detailed explanation of the fuel transfer process for Ford vehicles with dual fuel tanks:
In Ford vehicles with a dual fuel tank delivery system, the system operates independently and automatically. The fuel pump in the front fuel tank delivers fuel to the engine. The front fuel tank acts as the primary source of fuel for the engine. When the fuel level in the front tank drops below three-quarters full, the system automatically initiates the fuel transfer process.
During the fuel transfer process, fuel is automatically transferred from the rear fuel tank to the front fuel tank. This transfer ensures that the front fuel tank remains between half and three-quarters full whenever there is fuel available in the rear tank. The system is designed to maintain an adequate fuel level in the front tank to support continuous engine operation.
The fuel transfer process is facilitated by a combination of mechanical and electrical components. Some Ford vehicles may have a low-pressure pump and sending unit in each tank, with a single high-pressure pump located on the frame rail. In other models, there may be a high-pressure pump module with check valves in each tank. The specific configuration depends on the vehicle's model and year.
The fuel gauge sender plays a crucial role in monitoring the fuel level in each tank. It consists of a variable screened resistor controlled by a float in the fuel tank. When the fuel level is low, the resistance in the sender is low, and as the fuel level increases, the resistance gradually rises. This information is relayed to the fuel gauge, providing an indication of the fuel level in each tank.
It is important to note that the fuel transfer process may vary slightly between different Ford models and years. Some vehicles may have a manual switch to select the active fuel tank, while others may perform this function automatically. Additionally, the presence or absence of a fuel tank selector solenoid or a Dual Function Reservoir (DFR) can influence the specific steps involved in the fuel transfer process.
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Frequently asked questions
The twin fuel tanks in Ford trucks are known as the primary and secondary fuel tanks. The primary tank channels fuel directly to the engine, and the secondary tank takes in fuel, depending on the fuel available in the primary tank. A single pipe connects the two tanks, and they work simultaneously. When the engine is turned on, the fuel pump activates.
The dual fuel tank is designed in two different patterns: series and parallel. The series pattern ensures that fuel flows directly into the engine, while the parallel pattern uses two different fuel pipes that meet at a junction.
There are several signs that indicate a faulty fuel pump in a Ford dual fuel tank system. These include:
- Excessive noise from the fuel pump.
- Difficulty in starting the engine.
- Jerking or sudden intervals of forward motion while driving.
- Insufficient fuel supply to the engine, causing the car to turn off unexpectedly.
