Inaccurate Fuel Gauge

[GMC]

I've converted my 96 smiley front to a Mondeo TD cluster with rev-counter etc. The fuel gauge has never been 100% accurate, but was always near enough.

However, over the last couple of weeks it's become increasingly inaccurate, eg, showing quarter tank when it's actually full!

Any idea's, are the sender units a common problem or maybe a gauge problem?

[MarkM]

I can't help directly with the gauge issue but if you drop by this thread (below) you will be able to help as other than you gauge as I assume your cluster is working correctly...also that thread might have the right people reading it to help with the gauge too..as at least one guy is up on the electrics or so it would appear

http://www.fordtransit.org/forum/viewtopic.php?t=4649

[AndyG]

Firstly check your earthing on your fuel tank sender unit
Now you can tell us if your;
A) Rev counter works properly
B)(I might know this one) Is your speedo cable driven (mechanical)
C)Had any problems with the the warning lights. (removed any/etc)

[Aquanaut]

I done a similar swap a few months ago, unfortunately the new clocks were from a Mondeo Petrol, but I went ahead anyway and even pulled a new pulse wire from Alternator.
I couldn't calibrate the rev counter correctly as it was designed for a petrol engine (Higher revs), that pissed me off as everything else worked ok.

I swapped over the internal guts from my original Fuel Gauge and when I knew I had a full tank I set the indicator hand to full.

Make sure you have the ignition on and that it is working before locking the hand in place.
I had no problems, but I changed back to old clocks as Rev Counter was useless which was the reason for changing.':cry:'
I'm still on the lookout for a Mondeo Diesel clockset with around 80k miles.

Dismantlers want too much for clocks 60 euro as they may think that we're fiddling the clocks in prep for sale, I think.