There wasn't a TSB when I had took my car. The Ford dealership had to do a lot of diagnostics work and consult with Ford Technical before they figured out the problem. There may be a TSB now as a result but I'm not sure as I didn't check, so it's worth checking if one got issued.

The dealership can fault diagnose the problem by testing the low fuel sensor on the back of dashboard/instrument panel, if the sensor is faulty then it won't be doing anything or if an intermittent problem then it'll toggle between no signal and the occasion signal.

If the dealership isn't willing or capable of doing this work then they shouldn't be in business, in which case find a more competent dealership.

The instrument/cluster panel is covered under warranty. It's easier for them to diagnose the problem with the fuel warning light on showing the 80 or so miles left until empty, so run down the fuel until the light just comes on and then take it into the garage.

Tell them to directly test the low fuel sensor functionality, that's where the problem lies. The low fuel sensor is fitted into the instrument/cluster panel and cannot be changed under warranty without changing the instrument/cluster panel, it's a fairly straightforward job for them to do. Expect approx. 4 to 5 day wait for the replacement instrument/cluster panel to arrive. Ask them for a courtesy car in the meantime if you need transport.

They are talking utter rubbish. The level of incompetence of some garages and Ford Technical seems to know no bounds. The garage I took my car wouldn't give up and neither would I.

This is not the first time this problem has occurred for Ford, if they haven't bothered to record the work done for my car and other cars then it's no wonder they claim the problem only existed on your car, they're talking utter rubbish.

They have to remove the instrument cluster panel and directly test the low fuel sensor functionality, the low fuel sensor will either not be working at all (as with my car) or only intermittently working, that's where the problem lies, if they are too lazy to do that then they shouldn't get paid nor have a job. It's utter rubbish them saying they have reprogrammed the software for the light to come on at 75 miles to empty, they may have blown in some fresh software (that's the lazy approach to problem solving) but that won't cure the problem as it's a hardware problem not a software problem.

Go back and tell them you don’t want the car back until they have taken off the instrument cluster panel and tested the low fuel sensor functionality, and whilst they are about it to fit a new replacement instrument panel. They can keep the car until they have completed the work. In the meantime you are entitled to a replacement courtesy car for the duration of the work, it's all covered under Ford warranty, you may have to pay for the courtesy car insurance cover and fuel but that's it. Be assertive and polite.