Question about Ford Windstar

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My first problem, given to you July 14, was about my fuel gauge being stuck on "empty", on my 1999 Windstar. Your first solution was to check the wire connecting to the fuel sender for corrosion. I cannot find the fuel sender on either the bottom or any of the sides of the gas tank. So, if it is on the top of the tank, under the floor, how do I access it in order to check the wire? And if I have to change the sender, can I do it without siphoning the gas or dropping the tank? Thanks for your help. BOB

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  • elbobroom Jul 25, 2009

    Hi Guru, Thanks for your words of instruction & CAUTION. I like the way you explain things. I will accept your "solution" yesterday as a birthday gift on my 75th B-day! I'm an Ole Amateur Do-it-yourselfer", retired Bell Telephone guy,who has worked on cars since the 1950's. I dropped the tank on my '67 Chevy Caprice, but that was in the '70's. Now that I'm in my 70's, I'm gonna pass on this one and go see my local Gas Station mechanic! I'll have more problems for you later. Thanks again. BOB

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Hi

Unfortunately to get at the fuel sender you have to remove the tank on this vehicle as the sender is situated in at the fuel pump.

See this thread near the bottom of the page where someone resolved a loose connection. The sender unit itself costs around $70.

http://www.ford-forums.com/electrical-lighting/15588-98-ford-windstar-fuel-gauge.html

You will have to jack up the rear as high as you can and secure on jack stands. The tank should be near to empty to assist during this process.

The tank is held is with two long straps. Also there is a filler neck and vent hose at the rear of the tank that will have to be disconnected. The tank will have to be lowered and removed. You will need someone to assist you doing this and a good floor jack. Place a piece of plywood between the jack and the tank to avoid harm to the tank itself.

Lower the tank slowly while disconnecting fuel lines and wires as they become visible.

Once the tank is removed, you will see the fuel pump where the sender unit is.

Its not an easy operation to get at it! If you are lucky the connection will be loose or corroded but you might think about having the part already ordered in case the sender itself is faulty.

Given the amount of work thats involved getting at this sender - I would be inclined to have the instrument cluster/gauges checked by a dealer before embarking on this mission! If they check out then you may decide to proceed as outlined.

Hope this helps. Please remember to rate my answer. Many Thanks.

Posted on Jul 24, 2009

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