Ford F77Z-9275-CA Sender Assembly

Raise the vehicle and support it securely on jackstands. Disconnect the fuel pump/sending unit electrical connector. On models through 2000, the fuel pump/sending unit electrical connector is attached to the left frame rail. Position the ohmmeter probes into the electrical connector and check the resistance. Using an ohmmeter, probe the terminals of the fuel level sensor connector to check the resistance. Use the 200-ohm scale on the ohmmeter. With the fuel tank completely full, the resistance should be about 160.0 ohms. With the fuel tank nearly empty, the resistance of the fuel level sensor should be about 15.0 ohms. If the readings are incorrect, replace the fuel level sensor. A more accurate check of the fuel level sensor can be made by removing it from the fuel tank and checking its resistance while manually operating the float arm. A more accurate check of the fuel level sensor can be performed with the assembly on the bench. Connect the ohmmeter probes to the connector and check the resistance of the fuel level sensor with the float positioned on "empty" and ''full". Check for a smooth change in resistance as the float is moved between the positions. Remove the fuel tank. Remove the fuel pump module from the fuel tank. Remove the fuel level sensor mounting bolt(s) and electrical connectors from the fuel pump module. Installation is the reverse of removal.

Set the vehicle raised on jackstands, then use them to keep it firmly in position. Take off the connection for the fuel pump/Fuel Level Sensor electricity. Place the ohmmeter probes into the electrical connector and use the 200-ohm ohmmeter scale. To check the sending unit, we measure resistance between the electrical connector with a full fuel tank (which should be about 160.0 ohms) and then wait for the fuel tank to almost run out (when resistance should drop to about 15.0 ohms). When a sending unit shows faulty readings, replace it immediately. Take the sending unit out of the fuel tank, then test its resistance manually as you move the float arm. With a multimeter, hook up the leads to each cable of the sending unit and look at the results as you push down the floating part when it's both empty and full. See if the readings change evenly across this range. First, pull out the fuel tank. After that, take the fuel pump unit off the tank. Loosen and detach all sending unit bolts from both the module and the fuel pump. Also make sure to remove the electrical connectors. Installation is the reverse of removal.