Just had to replace my fuel pump at 81,000 miles. When I got my 2005 focus it had 22,500 miles on it. Before the fuel pump went out, the low fuel light would come on when there were 2 gallons left in the tank, but since getting the new pump, the low fuel light comes on when there are 4 to 4.5 gallons left in the tank. I took it back into the dealer and they tried to "fix" this, but it didn't make any difference. I first noticed there might be a problem when I filled up the tank and the gauge didn't even make it to the full line. I commute 200 miles to work everyday and am upset that I can drive one way to work on E (100 miles). I don't think there is any way to fix this. The fuel pump is inside the tank so it takes a couple hours to take it apart and put it back together. I was told the wiring has to make an "S" and it might not be.

I am having a problem with my gas gauge reading E while it has 3 - 4 gallons left in the tank. How I know.. every-time I fill the tank, it takes approx. 10.5 gallons from E. The manual states I should have a 14 gallon tank. I have been driving my car about an 1/8th past E, and when I can't stand it any longer I fill the bloody thing.. only to realize I still have 1.5 gallons left. Not that I wish to run dry, I have taken my focus into ford and have yet to hear a good reason for the gauge. The best so far, ford designed the focus with a 4 gallon reserve, it is supposed to be this way!

6/22: Just got back from the ford dealership, here is their answer to the problem above. I will quote ford directly, from their printout: "The owner's manual advises the amount of usable fuel in the empty reserve varies and should not be relied upon to increase driving range." Thanks, 4 gallon reserve! My Nissan Xterra didn't have a 4 gallon reserve!!! Looks like I am going to have to dig deeper, I can't be the only one with this problem.

I am curious if anyone else has had a similar experience with the gas gauge, fuel module or tank. If there is a known fix, I would love to hear about it. Thank you