Hi - I have a base-model Santa-Fe 2004. Recently, I found the fuel gauge to be registering zero and in fact the "No Fuel" warning light was on. I immediately pulled over and started pumping in fuel but registered a full tank when it was only about 10 gallons. The fuel gauge now showed "Full Tank". When about half-empty tank again the needle dropped to zero! This has happened multiple times. Went to AutoZone and they didn't find any error code registered in the OBC. I am confused. It's still under the 5-yr warranty but at the same time dealership here is horrible... they might give me a ****-and-bull story and subsequently charge me. Please advice.

The Santa Fe's fuel tank is designed in a so-called 'saddlebag' shape as it has to clear the center propshaft in the 4WD models. Even the 2WD models have this fuel tank shape, obviously to reduce manufacturing costs. Because of the design of the tank, there are two sender units, one in either side. It averages each to most accurately determine the amount of fuel in the tank. Chances are you've got a bad contact in one side or one sender unit has gone bad. I'd get it into your dealer and have them check to make sure the floaters and the related sender units are working properly. I think they'll find something is not right.

Thanks. Wondering if there would be a charge associated with this? It's still under the 60,000 warranty / 5 yrs. however I am the 2nd. owner. Also, in case covered - then the 2nd. question - what - related to this - might NOT be covered, as this dealership has a habit of (a) Pulling a fast one (B) Indicate irrelevant issues as if related to this and then do a charge-back.
As an example -> I once had an issue with brakes and as per them it's due to weak battery and asked me to replace the battery, which was as per them $275.00 (US).
Thanks again for your response. Appreciated.

I have a similar problem on my '01 with the fuel gauge showing empty after about 180-200 miles and the tank being full when I put about ten gallons in it. It looks like one of the two fuel level sender units has gone bad, or maybe a bad connection.

Where are the fuel sender units located? How are they accessed? I'm hoping the Santa isn't one of those cars that needs the gas tank dropped to access the sending units!