All, I just swapped the 33 gallon tank over this afternoon with one of my mechanic buddies and everything is working as it should for the most part. Truck starts, runs, and drives fine but I am getting a check engine light and error code P0460 stating there is an error with the Fuel Level Sensor. Has anyone ran into this before? The check engine light came on immediately upon starting and everything appears to be correct from what we can see. The only issue is the fuel gauge on the cluster is not reading whatsoever. It shows completely empty. I confirmed that the tank capacity was updated properly with AlfaOBD, and I filled the tank after hoping it would clear up the issue but no dice. I can clear the code but it returns immediately. Anyone encounter anything similar or have ideas? Going to drive and burn off some of this fuel before we drop the tank again on another day to dive back into it, but was hoping someone might have some additional insight. Thanks.
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Finally got this sorted out, and we were actually able to identify the issue really quickly. After dropping the tank for a second time, we decided to start with the fuel pump harness given the nature of the trouble code. Everything appeared okay at first glance, but when inspecting the connector we came across a damaged wire (blue w/ white tracer). The wire broke inside the connector at the physical pin, and when we gave each wire a pull during our inspection, this wire pulled right out of the connector.
Again, we were super careful while we did this project and we never allowed the tank to hang freely or create tension on the harness, but I guess at some point we managed to do something that this wire didn't agree with.
We disassembled the connector, replaced the pin, and repaired the broken wire. Check engine light is gone and the fuel gauge is reading properly!
Not an ideal situation, but a very quick and painless repair. Officially in the 33 club!