PCM Detected Fuel Level Signal In/Out if Range??

[lazynorse]

Only 4600+ miles on the odometer, I got a solid check engine light on the dash. Drove fine, shows 3/4 gas tank.

My Ford Pass app explains the check engine light as:

“The powertrain control module detected the fuel level signal repeatedly moved in and out of normal operating range.”

Then, suggests I schedule service ASAP. I’ve not had the code read, but the internet seems to correlate my alert with PO461. Might be bad wiring or sensor associated with float in the fuel tank.

Annoyed I have to deal with this before 5000, hopefully the dealer can tack this on to my scheduled oil change in about 10 days.

Assume its safe to drive, if its just a bad signal telling fuel amount?

Anyone else have this problem?

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[Joeiconic]

A similar recent thread, but it doesn’t appear the poster reported the outcome.

https://www.ranger5g.com/forum/threads/fuel-level-signal-while-off-roading.26102/#post-599504

 

[airline tech]

Might just be a momentary glitch , with Forscan you can perfrom a IPC self test, this will test the fuel gauge and sender

PCM P0461:00

Fuel Level Sensor "A" Circuit Range/Performance: No Sub Type Information

Sets when the PCM determines the fuel level input signal repeatedly moves in and out of range, exceeding the minimum or maximum allowable calibrated parameters for a specified fuel fill percentage in the fuel tank. Follow the pinpoint test using the Diagnostic Trouble Codes (DTCs) set in the IPC .

 

[jlewand3]

Did you get this fixed? I've been having the same error lately and waiting for my service appointment.

 

[lazynorse]

Did you get this fixed? I've been having the same error lately and waiting for my service appointment.

Its at the dealer, awaiting parts shipment. Requires replacement of sensor or maybe other components within the fuel tank. PO461 was the code. Bad fuel level sensor. Only ~4900 miles on the truck. Inconvenient and disappointing, hopefully its a fix that lasts a couple hundred thousand miles. No car I’ve owned ever had that problem. So far, this is the only problem, knock on wood. Love the truck otherwise!

 

[jlewand3]

Thanks! Sounds like we'll have the same solution from service. My fault goes on and off, for the past few months.

 

[miraculon]

My '22 Ranger has this problem whenever I come close to filling the tank. After the gas pump shut off, I did a "single click" of the pump nozzle one time and since then I get the "Check Engine" icon and the "The powertrain control module has detected that the fuel level signal has repeatedly moved in and out of the normal operating range." PID. Once the tank empties to about 3/4 full, the MIL goes out and the codes clear by themselves. I have been putting in about 5-6 gallons at about 1/4 tank recently, but today the MIL lit up again.

Just for the heck of it, I enabled the Engineering Test Mode (EM) with the OK button and ignition on. There are several fuel level displays, but I chose this SFS one, I don't know what the other modes are.

Interestingly, the "Inst Fuel" drops to zero (0) intermittently while the FLPM (Filtered) on is fairly steady. I tried this when the MIL was not lit and it was about a half tank, and it didn't exhibit this behavior. You can see the Inst Fuel dropping out. This must be what is triggering the MIL. Still no word from the dealer about a replacement sender...

The rain sound was added because the XM Sirius radio was playing, and I wanted to mask out the music somewhat.

Greg

 

[lazynorse]

My '22 Ranger has this problem whenever I come close to filling the tank. After the gas pump shut off, I did a "single click" of the pump nozzle one time and since then I get the "Check Engine" icon and the "The powertrain control module has detected that the fuel level signal has repeatedly moved in and out of the normal operating range." PID. Once the tank empties to about 3/4 full, the MIL goes out and the codes clear by themselves. I have been putting in about 5-6 gallons at about 1/4 tank recently, but today the MIL lit up again.

Just for the heck of it, I enabled the Engineering Test Mode (EM) with the OK button and ignition on. There are several fuel level displays, but I chose this SFS one, I don't know what the other modes are.

Interestingly, the "Inst Fuel" drops to zero (0) intermittently while the FLPM (Filtered) on is fairly steady. I tried this when the MIL was not lit and it was about a half tank, and it didn't exhibit this behavior. You can see the Inst Fuel dropping out. This must be what is triggering the MIL. Still no word from the dealer about a replacement sender...

The rain sound was added because the XM Sirius radio was playing, and I wanted to mask out the music somewhat.

Greg

The part, located in the fuel tank, was replaced under warranty for me. Happened in the first 5000 miles.

 

[airline tech]

The fuel level input is powered from the IPC sending a reference voltage to the Fuel Level Sender in the tank, the in-tank sender uses a dual sweep resistor (2 resistors) on a single return circuit back to the IPC for a reference return voltage - This voltage return shows the fuel level, and the resistance depends on fuel level, higher resistance when empty 180 ohms and 10 ohms full.

There are a few different fuel gauge readings you will see, depending on the type of failure, but it appears one of the resistor readings is out of range and you still have an accurate fuel gauge reading.
Most of the time, fuel gauge issues happen in the 3/4 to Full range as that is where it spends the most time.

The code you have appears to be the most common and I think it ties to (one) resistor being askew.

My wife had a 2002 Blazer, its fuel pump assembly was replaced 5 times in the time we owned it.
3 of those times were due to the Fuel Gauge (Jumping) when it was between 3/4 and Full.
The engineering design sucked and was prone to fail, let's just say I got very proficient at dropping the tank and replacing the pump assembly as the last pump change, I was done in about an hour with a full tank that had to be removed, the Blazer had an anti-siphon block in the fill tube, so it made it difficult to manhandle down to the ground.

Pic showing the Fuel Level sender, the little finger (tabs) glide along the circuit board (resistor)
The finger tabs wear down (small spring loaded) and the circuit board contacts wear down as well.
So, using this pic, with the float all the way up (Full) the finger tabs will move to the right side of the resistance scale.
The Ranger incorporates an Anti-Slosh mode (default) this is why you are not seeing the gauge jump as I did on the Blazer.

 

[miraculon]

Thanks for the explanation and detail. I wonder if the other fuel level display modes are for these two sender resistive elements.

Next time I fill up, I will check those other display modes and compare them.

Still haven't heard from the dealer. I don't know if this is a part shortage or what...

Greg

 

[Fx4ranger2019Larait]

Still haven't heard from the dealer. I don't know if this is a part shortage or what...

Greg
[/QUOTE]

It’s in stock on rockauto 52$

 

[miraculon]

It's at the dealer today, they are going to change the sender. Finally!
The service manager said that this is their third 2022 Ranger with this problem, and they have only seen this issue on the '22's.

I live in a small town and this isn't a big dealership.

Greg

 

[miraculon]

Dealer replaced the sender and it seems to be working well after a fill-up. (no extra clicks!)

The Engineering Mode display as I posted previously, shows a steady reading when stopped (while full) and only changes during deceleration. I suspect that as the tank empties it will slosh to a higher number, so far only goes down a bit. Not dropping to zero like it was.

The service writer guy said that Ford changed the sender design and it looks different from the old one.

Greg

 

[Jacob]

I’ve gone over 100k with this problem on my 2019. Honestly for those that get it. If you have to pay for the repair, might as well wait for the fuel pump to go out and get both changed.

 

[westexin]

I just started seeing this issue on my 2021. Not sure how serious it is overall. Has it caused anyone any serious issues?

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