jlupicki

My 2010 F150 5.4 won't start after filling the tank. Filled up with e85 with the tank almost empty and went to leave and the truck wouldn't start. Had to press down on the pedal like the owner's manual says to get going.

Filled up with normal gas and it did the same thing.

Now the darn thing stalled at the end of an exit ramp off of a highway and wouldn't start.

I had half a tank when I left, drove 14 miles and it warned me that I was running out of fuel. I could see the gauge falling to the 'E'. I filled it and it only took 18 gallons and now the gas gauge shows less than full.

What the hell?

Razorback150

Sounds like the fuel pump. I had a Chevy S-10 that did the same thing before the fuel pump went out.

jlupicki

Well the truck was at the dealer for the issues of not starting after refueling and the inaccurate gas gauge. Big surprise that there were no codes so they didn't know what to do. They did say that I caused this by over filling the gas tank. They basically sent me on my way.

They said there was a re flash for the gas gauge but that has proven just as unreliable so they elected not to do it.

Now when I have 15 gallons in the tank the truck warns me that there are 0 miles to empty and my GPS shows me where every gas station is.

Really happy it is out of the bumper to bumper warranty period...

Does anyone have any ideas?

fordfan77

Mine has had problems stalling at low speeds and also not starting after filling up. I don't fill it to the brim either. The last time it happened, I just reflashed my SCT tune and adjusted the idle rpm up 100 rpm, no hiccups yet. I was suspecting the throttle position sensor at first. Also twice the light came on with codes for the o2 sensors, the rear ones I replaced, but not the front ones yet.
Keep us posted.

texasgator

My truck just did the same thing yesterday - gas guage fell extremely fast, then truck stalled out at an exit ramp. Wouldn't immediately start back up again, but got it going enough to a gas station eventually. Filled up with gas, tank wasn't empty, only took 22 gallons. After filling up, fuel gauge didn't say Full. Did you ever find out what's wrong with your truck and get it fixed? Mine's going to the dealer tomorrow.

fordfan77

Since my previous post, I have not had any of these issues again.

jlupicki

The gas gauge issue on my truck was fixed by replacing the fuel level sending unit which requires the gas tank to be removed.

The issue with not starting after fueling was fixed by replacing some sort of valve that is on the intake manifold somewhere. I suspect this has something to do with the stalling also.

Both of these things were NOT covered by the warranty. I was just barely out of the 36K window and so that is that. Be prepared for big bills.

fordfan77

Do you know the name of the valve you replaced?

texasgator

None of that was covered under the powertrain warranty? Crap. Luckily, I bought a third party extended warranty when I got the truck. Seeing as how I'm at 38k miles now I'm guessing it'll save me a lot of money.

jlupicki

Ford worked with me on the fuel sending unit. The dealer charged me $85 to diagnose the problem. This is funny because I brought the TSB printed out for the exact problem.

They told me that it was going to cost over $500 to fix it. That is when I called Ford directly. They opened a case and worked with the dealer. It wound up costing me $97

Personally I think that if there is a TSB for some issue the work should be considered warranty. There wouldn't be TSB's if there weren't issues. A fuel sending unit should be covered.