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Car Forum / Ford / Ford Cars / August 2004

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Mercury Cougar, 1985 - Fuel Gauge reads wrong

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Wolfman - 17 Aug 2004 19:47 GMT
I own a 1985 Mercury Cougar.

My fuel gauge functions, but always shows far less than it should (top
20-25L at best?).

Suggestions?

Do I need to replace/adjust the float, or might it be more?
What should I check?
Can I adjust/change the float without dropping the tank on this (any) model?

wolfman@telus.net
Steve Stone - 19 Aug 2004 02:53 GMT
> I own a 1985 Mercury Cougar.
>
> My fuel gauge functions, but always shows far less than it should (top
> 20-25L at best?).
>
> Suggestions?

I had an 85 T-Bird which is pretty much the same car as your Cougar.
If you live in an area where the road crews use salt in the winter expect the top of the
gas tank to rust and perforate. DO you smell any gas when you fill it up ?
The fuel pump filter assembly is held in the top of the tank by a ring that gets very
rusty. Once you take an original pump out expect to replace the entire assembly including
a new locking ring and maybe a new tank as well. Accurate fuel gauge readings are hampered
by poor electrical grounds and the use of a marginally working voltage regulator attached
to the back of the instrument cluster. As these cheap regulators age they don't provide
the proper voltage to the gauges (think it was 7.5 volts) causing all kinds of misleading
things to happen to the analog gauges. You won't see this if you have the full digital
dash. The cluster is a real pain to take out from what I remember. In 230,000 miles I had
the cluster out at least three times for replacing the halogen lamps for the LCD speedo
display and once removed the entire dash to replace the heater core. One of the ugliest
jobs I've ever attacked.
Wolfman - 19 Aug 2004 19:16 GMT
> DO you smell any gas when you fill it up ?

No more than is usual (any vehicle, any time) when near the pump during fill
and nozzle extraction.

There is no obvious evidence of leaking. My fuel consumption is quite low
(for my limited experience). A full tank lasts more than 400km, driving back
and forth to work (10-15mins, 50-60kph) every weekday, and toodling around
town the rest of the time.

> As these cheap regulators age they don't provide
> the proper voltage to the gauges (think it was 7.5 volts) causing all kinds of misleading
> things to happen to the analog gauges. You won't see this if you have the full digital
> dash.

I have partial digital. The fuel gauge is an analogue needle.

> The cluster is a real pain to take out from what I remember. In 230,000 miles I had
> the cluster out at least three times for replacing the halogen lamps for the LCD speedo
> display and once removed the entire dash to replace the heater core. One of the ugliest
> jobs I've ever attacked.

Ouch... I hope I won't have to do that for a while! (at least until I have
to restore it)

Thank for your time Steve. I'll definitley probe a little deeper.

Wolfman
 
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