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I take my tank down to empty a lot, but I have friends who are the 'never below a quarter tank" types.
All they do is work and home (and in the DC are where there's a gas station everywhere you look). -- It's not like they're going to get stuck on a mountain pass or something -- geez.
I have a 2002 Camry and when the needle is on empty, I have put a little over 17 gallons in the tank. So I guess there is still a gallon or so in there at that point. However, I did notice hesitation when driving when I let it get to this point.
In most Chevy trucks it comes on at about 35 miles. Anything below 20 miles will read low fuel level.
I had a Duramax that occasionally would never show the low light but run out of gas in the process. Happened 3X in 100K miles so I got out of the habit of waiting until the light came on.
My F150 light comes on at about 50 miles to E. Waiting to fill up when the light is on is a mistake waiting to happen. You will eventually burn up the fuel pump, but not only that could run the risk of running out before making it to a fuel station. The gauges and lights are not exact, so trying to run as close as you can to E could have you walking. My rule of thumb is at 1/4 of a tank I'm looking for a station.
I recall old VWs had a spare tank( or a petcock arrangements like on motorcycles) that you could switch on manually.
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