2000 Ford TE50 Pricing and Specs

I'd say you're looking at two different problems here, neither one of which involves the actual fuel tank (which is, indeed, 55 litres). The first problem is more likely to be the calibration of your fuel gauge that is out. If the gauge isn't reading accurately, it will tell you the tank is emptier (or fuller) than it really is. Your car is actually doing what most fuel gauges do, which is to be a bit pessimistic, suggesting there's not as much fuel still in the tank as there really is. You could have the gauge recalibrated, or simply know that even when the needle is at empty, you've still got a buffer zone of fuel remaining.

The fuel consumption, meanwhile, is another issue and it's true to say that 20 litres for 140km of driving is too thirsty. A basic tune up might help, starting with fuel filters, air cleaners and spark plugs. But don't ignore things like correct tyres pressures and whether there's a roof rack fitted; these things will affect fuel economy more than you might imagine. And never under-estimate the affect driving style has on fuel use. A driver who smashes the throttle from every green light will soon start using more fuel every kilometre.

The original vane-type oil pump fitted to the 2.2 and 3.2-litre PX Ranger engines was a source of great misery for some owners with failures and a peculiar oil-changing regime forced upon owners. If the gear-driven style pump you've replaced it with is a good quality item, it should last the remainder of the vehicle's service life.

It sounds like your diagnosis that the vehicle went into Safe or limp-home mode is spot on. Being fully loaded and travelling at speed up a long hill on a super-hot day could certainly be enough to make the car enter limp-home mode for its own preservation. This is confirmed by the fact that after a break and downhill run, the temperature stabilised and the car came back to full functionality.

Modern turbo-diesel engines make lots of power and torque these days, but they do that by burning fuel and that creates heat. You might also find that the limp-home mode initiation was at the behest of the transmission which would also be damaged if it got too hot.

Car-makers have designed these limp-home modes to protect the vehicle from permanent damage in severe operating conditions, and in your car, it seems to have done its job perfectly. The only unknown is whether the limp-home mode was initiated by the conditions or something actually wrong with the vehicle. It would be wise to have it checked over to make sure the cooling, fuel-injection and transmission systems don’t have a separate problem that is causing the Everest to enter Safe mode.