2021 XLT cut out and fuel gauge issue

[railsandtrucks]

Got my first problem cropping up on my 21 XLT 4x4 I picked up in April of last year. Truck has 22000 miles on it, all by me.

Thursday morning of last week I got a low fuel warning as I went to work, both via the trip odometer and the gauge itself. Thought that was odd since I'd just filled up the day before but figured maybe someone had siphoned gas. Stopped for fuel on the way to work and the truck only took 5 bucks worth of gas.. after refueling gauges went to normal.

Then coming home from work that afternoon, the truck completely lost power on me while driving- gauges went back to zero/dash display blanked out before a message popped up telling me to place the truck in park before restarting. So I Stopped, put it in park and it drove the rest of the way home just fine.

My dealership couldn't get me in/no loaners available and I had to drive out of town for work today/Sunday for the week. We'll, this morning the fuel gauge did the same thing, then after about 15 minutes of driving started working again (this time I ignored the low fuel as i knew i had around 3/4 tank). After over 150 miles of mostly freeway driving today, the truck cut out on me again, so I got it onto the shoulder, restarted, and it made it the last 30 ish miles to the hotel with no issue.

Anyone experience anything similar/have any ideas?

I thought at first maybe bad gas/water/condensation in the fuel system (I live in the Detroit area and am working in Indiana this week) but the fact that it's cut completely out like that twice concerns me.

There's no check engine light on or other error messages popping up. Truck has been nearly flawless otherwise.

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[Frenchy]

Sounds lile a first to me. What could be the cause? Possibly the fuel pump assembly could have internal issues. If not that maybe an internal issue with the PCM(programming or hardware possibility). If you have a tine I suggest going back to stock and seeing what it does. If it goes back to normal.and doesnt act up then the tune is the cause and needs to be fixed. If not tuned definitely have the dealer look at it as soon as possible.

 

[WNCblueridge]

Dang. thats weird. I am interested to see if anyone else experienced the same.

 

[9zero1790]

havent had that happen. The fact that it restarted and drove home fine makes me think it could be battery, wiring or voltage related. id start by checking the battery connections and make sure they are all tight. Check the battery to see if it is testing good.

 

[Jason B]

If it's a fuel delivery issue and a fuel gauge issue, first thing I would check is the connector and wiring going into the tank.

 

[D Fresh]

If it's a fuel delivery issue and a fuel gauge issue, first thing I would check is the connector and wiring going into the tank.

This.

Also, did you have the truck underciated? There have been issues with undercoating, mainly fuel breather issues, but this could be contamination in an already loose plug.

 

[railsandtrucks]

Appreciate all the replies everyone! Definitely good places for me to start. Unfortunately I worked a bit late today and didn't really have a chance to check things. Truck seemed to run OK today but I only had a 10 min drive each way into the plant. I did run low enough on fuel for the low fuel warning to correctly kick in (I've since filled up) and interestingly the check engine light also came on and stayed on though the engine seems to be running OK.

As for some of the ?s posed, truck does not have any aftermarket tune and I never wound up getting an undercoating, I've just been washing the truck every 7-10 days instead since the roads have started to be salted/brined.

Not sure if I'll be able to get the truck in anywhere till Wednesday with my work schedule Unfortunately, but at the very least I plan on checking some of the connections tomorrow as suggested. Really appreciate everyone's input and help!

 

[KJRR]

Appreciate all the replies everyone! Definitely good places for me to start. Unfortunately I worked a bit late today and didn't really have a chance to check things. Truck seemed to run OK today but I only had a 10 min drive each way into the plant. I did run low enough on fuel for the low fuel warning to correctly kick in (I've since filled up) and interestingly the check engine light also came on and stayed on though the engine seems to be running OK.

As for some of the ?s posed, truck does not have any aftermarket tune and I never wound up getting an undercoating, I've just been washing the truck every 7-10 days instead since the roads have started to be salted/brined.

Not sure if I'll be able to get the truck in anywhere till Wednesday with my work schedule Unfortunately, but at the very least I plan on checking some of the connections tomorrow as suggested. Really appreciate everyone's input and help!

The code may be a clue. Stop by your local auto parts store and get the code read.

 

[railsandtrucks]

Good Morning,

Quick update - Was able to take it into a local dealership yesterday and they were able to give me a ride to work. By the time I got off duty and got back to them, the tech was just finishing up diagnosing.

I don't recall the exact codes- but they were both fuel pump/sending unit related, although they did manage to clear themselves. Tech is going to replace the pump/sending unit and I was able to grab a rental car in the meantime. Dealer should have the new pump by friday and I should have my truck back by end of this week or early next. Hopefully this fixes the issue, though I'll keep everyone posted.

Really appreciate all of the help so far!

-Karl

 

[railsandtrucks]

Ok, I have another update.

I've had the truck back since Tuesday - dealership in Indiana was awesome in regards to service, honestly wish they were closer than 3+ hours away. Smaller shop, and was one where I actually got a chance to talk to the tech. Tech and service staff were both top notch.

For about the first 24 hours I had the truck back, everything was normal, then I started having the fuel gauge issue again and upon starting up the truck a couple of the sensors (cross traffic/blind spot monitoring) said they were no longer functioning. Truck was a little dirty from road spray/salt, so I decided to take it through one of the local drive through auto washes. Once the sprayers hit the trucks dash went crazy like a vegas slot machine with all sorts of sensor warnings. Fuel gauge went up, then back down, then up again and then back down. Check engine light wound up popping on me again too after I drove out of the wash.

I was only in Indiana for work through last week, so I drove home yesterday- with a little driving the sensors started working normally, aside from the fuel gauge (which, seemingly at random, would raise for a bit and then lower again). I couldn't remember how much fuel I had, so I stopped for gas about halfway home- truck took about 2/3 of a tank which was less than I expected. A little more driving, and the check engine light turned off by itself before I could swing by anywhere and have the code ran. As of getting home yesterday evening- fuel gauge and all sensors working as normal.

At this point, best I can tell, it's some sort of electrical gremlin somewhere. Tech in Indiana had thought if it wasn't the fuel pump/sending unit that it could be somewhere in the dash, but the fact the truck acted up so much in the car wash has me wondering if it's something under the hood somewhere ? I'm tempted to go through another drive through auto wash and see if that sets the truck off again.

Open to suggestions /thoughts /advice? Should I try reaching out to Ford Corporate on this one ? I realize the local dealership is probably going to need the truck for a while and will hate troubleshooting these types of issues but I need this fixed. Seems like I was able to get around 27 mpg on the way home on Friday, so it appears the truck is running reasonably well. I'll be local for work for the foreseeable future in that I'll have a 30-40 mile commute each way.

 

[Frenchy]

Sounds like you have an issue with a harness somewhere. Definitely worth taking back to the dealer for a check. Sounds like you may have gotten an unlucky lemon. Hate to say it but it can happen

 

[JDowns]

My first thought would have been the fuel tank control module located on the frame near the spare tire. Its forward of the vehicle, almost center near the spare tire. Looks like this.

But with the car wash causing all the other issues I would lean toward a bad seal / connection at the main wiring harness junction, mid body on the main frame, with water / condensation corrupting the signal(s). You can't miss the junction. It's basically lined up with the drivers door. Odds are good the gasket on the connector is bad.

 

[P. A. Schilke]

My first thought would have been the fuel tank control module located on the frame near the spare tire. Its forward of the vehicle, almost center near the spare tire. Looks like this.

But with the car wash causing all the other issues I would lean toward a bad seal / connection at the main wiring harness junction, mid body on the main frame, with water / condensation corrupting the signal(s). You can't miss the junction. It's basically lined up with the drivers door. Odds are good the gasket on the connector is bad.

Hi Jeff,

I agree....the frame rail harness connector might not be completely seated. Pull apart...spray WD40 to chase away any water followed by Electrical contact cleaner...Inspect the gasket, and if good, Then reseat the connector until you get a audible click and cannot just pull the connectors apart...

Best,
Phil

 

[Toytec]

If it's a fuel delivery issue and a fuel gauge issue, first thing I would check is the connector and wiring going into the tank.

This is the first thing I thought of also^. It took 22k miles for this to happen. I'm thinking rodent? Wiring partly exposed? You might want to crawl down there with a strong light and an inspection mirror to have a close look see.

 

[Frenchy]

While thinking about it there is a pretty big connector right in front of the fuel tank. Worth checking there just to see what you have

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