Question about 1992 Ford F150 SuperCab

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Ford Dual Gas Tank problem, Rear tank Always full.

Here is the deal... I have 1991 club wagon with dual gas tanks. If I fill up both tanks full then drive on the rear tank for say 150 miles, then go and try to fill up the rear tank, it is full !! Well if I go and then fill up the front tank which has not been selected, it is almost empty!!! What??? I recently had all three fuel pumps replaced, and I am questioning the job they did. When I was having problems with the van, they told me it was the fuel pumps, but it wasn't. I ended up troubleshooting it and found a bad wire that was causeing all the problems. That being said on top of it all, the fuel sending unit in the front tank reads half a tank when it is empty, no bueno. I can listen to the fuel pumps switch from front to back as the toogle is thrown, but how is it possible that the tank is full after driving for hours on it? So what's the fix, or the exact problem? Does anyone know? Mine's a '92 F150 so obviously I have been living with the problem for over 15 years. Lately, with gas prices the way they have been, I've only been filling the front tank. I was reminded of the issue again the other day when, with gas at $1.75(california), I filled up both tanks. My truck predominately fills the rear tank when running off the front, although it will happen the other way sometimes. I just use the tank switch a lot. But does anyone know the cause of the problem? I took it to my local dealer years ago, they had it for a week, and gave me some song and dance about having to remove the bed, but never did anything. Seems like it ought to be pretty straight forward, the excess fuel from the fuel line is being returned to the wrong tank. But what part has failed?

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This is a common problem. On the driver's side frame rail is a large black plastic assembly that the fuel lines connect to. This a fuel switching valve what usually happens is the valve goes bad and the fuel gets pumped from one tank to the other

Posted on Dec 09, 2008

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