My fuel gauge is doing eratic stuff. I start the truck in the morning and it's empty, then sometimes it will start to read correctly, then it goes all the way full. Mostly it stays on empty though.
I suspect a wire broken someplace. Has anyone else run into this? Was it a broken wire? If so, where did it break.

Thanks,
Chris

 

Stamey, my 98 does the same thing. It is really common. The sending unit in the tank has a bad habit of going bad. A while back someone had a fix posted here, but I have not fixed mine yet. I have been driving on the odometer since I bought the truck about 2 years ago. Next time I have the bed lifted I guess I'll fix it. The above fix was supposed to be easy to do.
Ed

 

Mr. Stamey,

I wrote in about this a couple of weeks ago. When all was said and done I dropped the tank and pulled out the module. I found that the slots were worn between the top half and the bottom half as most said they would be; however, this is not why it didn't work.

I pulled the float unit off of the module and found that the contacts were not making contact as they should. I bent the small contacts back down so they would make proper contact and hooked the gauge up under the truck...it worked.

Ah but don't stop there. If you drop the tank just go ahead and replace the float unit as I did (about$45) cause you'll be mad as heck if you have to drop it again.

All this was documented...it's probably 4-5 pages back if you look under "fuel Gauge". In fact you were the first to respond to me!! Hope this helps.

John

 

John,
Thanks for the reply. If I remember correctly, your gauge did not work at all, right? Mine comes and goes. Today it has read empty, correctly, 1/4 tank when the tanks was full, 2/3 of a tank when the tank was full, and when I got home it was reading just under full (probably correct).
Since mine is just going nuts I was thinking that it has to be a wire someplace, not necessarily the sending unit or gauge.

Thanks,
Chris

 

towin1JT
After going back to look at your post, it seems more relevant than I remembered. Sucks getting old. :
I will drop the tanks at the end of this week when I run that full tank I got on Friday out of it.

Just to clarify, you did not replace the sender, just the float?


Thanks,
Chris

 

Chris, I've heard others have removed the bolts and raised the bed instead of draining & dropping the tank.
Something to think about.

 

Yeah, I've heard that too, Ed. I'm thinkin it will be a little simpler for me to drop a near empty tank since it's just me, with no close help around, unless you're driving down. ;D

Thanks,
Chris

 

When I had to drop my step son's tank in his S-10 (insert yakking smiley here), I used my motorcycle lift with a piece of plywood on the top.
Worked well, made the reinstall go much easier.
You could probably use a floor jack but you'd have to balance the tank on it.

Ed

 

Shouldn't be too terrible. I have already dropped it half way once, when I installed my big-honkin steel braided fuel lines. ;D

Thanks,
Chris

 

Stamey,

Sorry I didn't reply sooner but I went on vacation the night I replied last. I towed my trailer up to Oregon and stayed right on the beach!! Took my 4-wheelers up and road on the dunes too!

Anyway, mine was doing the same thing yours was at first (acting wierd).

Oh yea, the float is the sending unit. What I did not replace was the entire module (what you pull out of the tank that incorporates the float sending unit - about $400 from what Iv'e heard). By the way the new float sending unit comes with a new gasket for sealing the module to the tank.

Hope you were able to fix it ok.

John

 

Dang. I guess I'm gonna have to drop the tank again. When you said float, I figured you meant exactly that, the float, since that comes apart separately from the sending unit.
When I dropped the tank this time is was an all afternoon job. The sending unit plug, for some reason, eluded me as to how it came loose. I pulled the red tab and it still would not come loose. By the time I figured out I had to pull the red tab all the way out I had already broken off the other tab that should be pressed, by pullling on it. I finally figured out to stick a small screwdriver in there and lift the locking tab. I messed with the return hose for about an hour, with breaks to cool off since I was getting so POed at it. I then went to the auto parts store and purchased enough fuel line to replace it, came home and cut it in the middle. Finally got the tank out from under the truck and the sending/pickup assembly out of the tank. I found the hose fitting for the return line was welded on. I could rotate it but it wasn't coming off. Spent another 30 minutes messing with that, and finally cut it off with my plastic welder but cutting slots down the sides of the fitting and splitting it.
Then my big honkin fuel line did not want to reconnect to the tank properly, kept slipping as I tightened the clamp, as I could only do it with one hand.

Much more of a pain than I figured it would be.

Chris

 

I am wondering if you have a different setup than my '97. The float complete with the two copper contacts and contact card that attaches (both mechanically and electrically with two wires) to the side of the module (the large assembly that actually mounts to the top of your tank with a large plastic spanner ring) makes up the float/sending unit. The float sending unit is one assembly only and is available form Dodge for about $45. This is the way my '97 was configured...again the float and sending unit (the contacts you bent back into shape and the card they slide on) are all one unit that I am calling the float/sending unit. Sorry you've had such trouble and hope this clears it up for you.

John

 

Chris,
Mine started acting the same way... way back when. Now it won't work at all. I've read how some guys have changed out a half dozen sending units on the same truck so I haven't bothered to do anything with mine like sherod said.
Maybe I'll change it if I decide to go to a larger fuel tank. :-

 

Yeah 46mech,

Mine went bad at 70K and I just fixed it at 123K (couldn't take any more spousel abuse...her truck you know!!)

John

 

Mine was bad when I purchased the truck, was totally empty while reading 1/2 tank. Took an entire day to change with my 13 year old son and 11 year old daughter doing most of the work ;D Mother wasn't to impressed when she come home and noticed how dirty they were....we lost track of time but had a lot of fun