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Discussion Starter #1
All the literature says my 2005 E150 van has a 35 gallon fuel tank. I tested my reserve by running the van until the low fuel warning light came on (and the needle was at empty) then filled up and it only took 29 gallons?

Explanation? Major reserve or a 30 gallon tank?
 

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They show a 37 gallon and 55 gallon aft axle fuel tank
Those low fuel lights are not always that accurate
 

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Wow did not know that kind of fuel capacity was available.
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Discussion Starter #4
So my van must have a reserve of 6 gallons (about 100 miles) after the low fuel light comes on. Is a reserve this big normal for Ford vans?
 

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Like I said before
Those lights aren't that reliable
I wouldn't let it go below 1/4 of a tank just to be safe not to let it get low and ruin your fuel pump
What does your manual say?
 

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The low fuel light was designed to come on when there is low fuel in the tank. There may be a spec but it is not commonly available. (May be in the shop manual)
It is not consistent over different model lines.

To understand how it works -
There is a thermistor that when exposed sends a signal to trip the light. The link below shows an in tank pump that has a sensor. It is not well pictured and the sensor is on the left side with a blue wire running near by. The end of the thermistor is some distance off of the bottom of the assembly. Is that distance 6 gallons?

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And 6 gallons is 17% of the full 35 gallon tank.
Likely a good place to trip the light.

You might be able to drop the tank and move the position of the thermistor if you wish.

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Discussion Starter #8
Like I said before
Those lights aren't that reliable
I wouldn't let it go below 1/4 of a tank just to be safe not to let it get low and ruin your fuel pump
What does your manual say?
The manual does indeed say 35 gallons. The gauge must be conservative. At a quarter full on the gauge it takes 24 gallons and on empty it takes 29 gallons. The warning light as expected comes on when gauge is just touching empty.
 

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Does his have a Mid ship tank?
The Ford catalouge said that they only had midships tanks in 2008-2010
But the make so many different ones its hard to say
I looked it up for his truck under the Chateau and they just listed rear tanks
 

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This is From Rock Auto
Rear tank
LILAND GLOBAL FOR03SS {#2C2Z9002GA, 4C249K087DD, F7UA9002CD} Stainless Steel; Lock Ring Kit Included Info
Rear; 35-37 Gallon Tank
Mid ship
SPECTRA PREMIUM F41C {Click Info Button for Alternate/OEM Part Numbers} Lock Ring Kit Included Info
Midship 35 Gallon Tank; 71 in. x 18 in. x 11 in
LILAND GLOBAL FOR06A {Click Info Button for Alternate/OEM Part Numbers} Galvanized Steel; Lock Ring Kit Included Info
Rear; 55 GALLONS
 

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Discussion Starter #11
Does his have a Mid ship tank?
The Ford catalouge said that they only had midships tanks in 2008-2010
But the make so many different ones its hard to say
I looked it up for his truck under the Chateau and they just listed rear tanks
Its midship
 

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Its midship
I should have asked that question a long time ago
The way the Ford catalouge is laid out
It points to aft axle
On your low fuel lamp
It should not wait until it goes to empty
It should alert you around 1/4 of a tank
 

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Discussion Starter #13
Thanks. I'm happy the way it is and have good safety. Even to when the light comes on I have a range of 500 miles so I'm OK
 
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