Engine/Transmission (1998.5 - 2002) 02 runs out of fuel at 1/4 tank, need fix ideas

[IC Smoke]

My buddy has a 02 CTD that has a stock fuel system except for a Holly Blue pump, the other day he made a turn and ran out of fuel, after talking to him over the phone I came to the conclusion its the pickup in the thank, so when he gets down to 1/4 tank it wont draw any more fuel..... how should we go about fixing this, I know the thank has to be pulled but is there a simple solution or does he have to find a fuel pickup unit to replace it? Ive heard of a few "draw straw" mods but Im not sure if that will do it since I havent opened up a tank or seen a "draw straw".....







Thanks

Ian Coleman

 

[JKinney]

The tank has got to be dropped and the components inspected, the module could have fallen apart which will cause loss of suction at about a quarter or the tank float is deteriorated

 

[Allnew2Me]

Mine was out of fuel even though it showed around 1/8 of a tank. The low fuel light never came on. I had the sender replaced and all is good. I would guess that his sender is showing 1/4 tank but he is much lower than that. The tank does have to be dropped to replace it.

 

[Spunkys Ram]

Mine did the same thing, it was the sender/float assembly had gone bad.

 

[CWolgamott]

mine does it as well however the tank is empty at 1/4 tank and still fills up the same amount as far as total gallons

 

[rweis]

There is a permanent fix to this, but it is somewhat involved. I have a thread about my experiences with it and how the fix went.



Probably not recommended unless you are going to keep your truck for a while as you have to modify the tank and install a totally different fuel level sender. Good time to put the DrawStraw in though.



Bob Weis

 

[fox]

Mine does this too.

I am sure it is a slowly plugging filter on the bottom of the pick-up module. I am also sure it is from bio diesel. Some stations are more prone to it.

Remove the module from the tank and clean the filter/screen with gas and it gets better.

 

[BarryG]

I have had two fuel sending units go bad and it seems to be a fairly common problem. There is a fix for the sending unit if that is what it is. Just do a search on that. The float also seems to be a problem for some where it has deteriorated. There are also some alternatives if either is the case. Rweis's fix is a comprehensive fix for the float and sender from what I have seen in that thread.

 

[IC Smoke]

what kinda prices have you guys seen on the sender/ float to fix the issue?



Thanks

Ian

 

[ERuhl]

First, are you certain the tank is empty when it reads 1/4 tank? How many gallons did it take to fill it at that point?

I just swapped out my draw-straw equipped module for the stock version because the draw straw would start sucking air under braking if I went below 1/8 tank. I still have the draw straw equipped module ready to drop in if you're interested in it. Saves you some fab effort and you can keep the original to switch back if you don't like it. Fwiw I see a 1 psi difference between the draw straw and stock pickups at WOT. Cruise psi is the same.

 

[IC Smoke]

he said it was at 1/4 tank and his mileage reflected it and he put in 10 gal, after bleeding the lines it took off and the fuel gauge came up (obviously) Ill take you up on the draw straw offer.



Ian

 

[Allnew2Me]

The first time it happened to me I ran out of fuel without the warning light ever coming on. I thought the LP was gone so I replaced it and all was good until a while later when I put 34 gallons in a 35 gallon tank. I had the sender replaced and that solved that. Next I noticed that my fuel pressure was around 6 on the freeway, it would go back to 14 and then drop again. I knew I had fuel. I still had the LP in the stock location so I relocated it at the tank and without changing anything else my pressure came back up. With a low tank the LP doesn't want to draw nearly as well as when the tank is full so that may be part of the problem also.

 

[EdK]

Why drop tank?

Why not cut a section of the bed floor out large enough to get to the sending unit, then tack it back when finished?

 

[Spunkys Ram]

Why not cut a section of the bed floor out large enough to get to the sending unit, then tack it back when finished?

OH, PLEASE DON'T. :{. . There IS a better way.

 

[EdK]

A truck!

It's a TRUCK!!! Maybe it's easier for me since I own a metal fabrication shop! Actually, I plan to fab a cover plate so it can be removed again when needed. Good engineering would have that access plate in the first place.

 

[rweis]

If these trucks were engineered right in the first place there would not be the critical need for TDR. The fuel cannister in an 02 is right below a bed stringer and right below the 5er hitch. Probably not a real good idea for 5er drivers.



Bob Weis

 

[IC Smoke]

ok what would fix it?

draw straw or a new pickup system?



thanks

Ian

 

[mhenon]

It's a TRUCK!!! Maybe it's easier for me since I own a metal fabrication shop! Actually, I plan to fab a cover plate so it can be removed again when needed. Good engineering would have that access plate in the first place.

Actually. . I like that idea! As I've kept my in-tank pump as a pusher to the frame mounted LP it would be nice to be able to get to it if needed.

How about posting a photo of the mounting plate when it's finished. Since you have a fabrication shop this could look pretty good.

Mike