2nd Gen Non-Engine/Transmission 2nd gen fuel gauges

[towner]

I have a 94 2500 4x4 with 88k miles my fuel gauge won't go above 1/2 tank... . my buddy a 97 3500 4x4 his truck wont go below half a tank and my third friend has a 98 12v and his tank is all over the place I think it follows the moon? Do these trucks have a problem with the sending units? They are kinda spendy and before I throw a bunch of $$$ at mine I was just wondering if I should look at something else?



Thanks for any help you can throw my way

 

[Joe G.]

The fuel level sending units are notorious for being a hunk of junk. I have replaced a few of them. Mine and some friends. Sofar the replacements are working ok.



You can check to see if your fuel gauge is working properly. You will have to either lift the bed or drop the tank to do any work on the sending unit. Pull the plug out of the sending unit. Turn the key on. The gauge should show empty. Short pins 2 and 3 (the two in the middle of the connector) together. The gauge should show full. It that happens then the sending unit is bad.



Edit. Forgot to mention. The Dodge dealer will want to sell you the whole tank module. The sending unit alone MOPAR part number is 4797738. It's about $75 or so. You might shop around and get it cheaper at NAPA or some other parts store.

 

[DonTX]

I just put on a new sender on mine, Jack Miller Jeep Kia in Kansas City has the MOPAR Nr 4797738 sender for $41. 40, feeling lazy so had a local shop put it on for $70. Sure nice to have a fuel gage again!

 

[WDixon27]

i cleaned repaired and tested mine (with a multimeter while moving the float, you want a smooth clean change in resistance) about 12k miles ago when i bought the truck with it dead, clean and retension the springs and contacts on the arm

 

[towner]

Thanks a lot... . just didn't want to throw a sender in and find out there was some other common problem. I appreciate your input

 

[Joe G.]

The retaining tab wears so the moveable part can move up a little. This reduces contact pressure on the variable resistor. It also allows the pin that the part rotates on to be below the top of the moveable part. This lets the top edge of the pin to wear a grove so the part wobbles. The result is that the fuel gauge may not work or it will be erratic. Cleaning and bending the contacts will fix it for a while.



I repaired mine. It worked fine but was off a little bit. I measured the resistance and found that it had little less than 12 ohms at full and about 113 ohms at empty. That was incorrect, it should be full 3. 8 ohms, empty 103. 3 ohms. So, after all that work, I replaced it. I don't think it's worth the effort to attempt to repair the sender. The repair won't last long because of the way it wears. The job is kind of a PITA to do anyway.

 

[satmike]

Are newer trucks (2001) the same part #

 

[Joe G.]

Probably is, but ask Dodge to make sure.

 

[Thomas]

Are newer trucks (2001) the same part #

No.


<TABLE cellSpacing=0 cellPadding=3 width="100%" border=0><TBODY><TR><TD class=titletext align=middle colSpan=4>Part Number Search Results : Mechanical Catalog </TD></TR><TR><TD class=tabletext style="BORDER-BOTTOM: #ff9933 1px solid">Item Number</TD><TD class=tabletext style="BORDER-BOTTOM: #ff9933 1px solid" align=right>MSRP</TD><TD class=tabletext style="BORDER-BOTTOM: #ff9933 1px solid" align=right>Core Price</TD><TD class=tabletext style="BORDER-BOTTOM: #ff9933 1px solid" align=right>Price</TD></TR><TR><TD class=tabletext vAlign=top>4897669AB </TD><TD class=tabletext vAlign=top align=right>$53. 35</TD><TD class=tabletext vAlign=top align=right>$0. 00</TD><TD class=tabletext vAlign=top align=right>$36. 80</TD></TR><TR><TD class=tabletext colSpan=4>Electrical - Chassis electrical - Senders - Fuel gauge sending unit

FUEL GAUGE SENDING UNIT, All Models, Gas Engine, All, 35 Gallon 2000 - 2002

</TD></TR><TR><TD class=tabletext style="BORDER-BOTTOM: #ff9933 1px solid" align=middle colSpan=4>Add to Cart Contact Us </TD></TR><TR><TD class=tabletext vAlign=top>4897669AB </TD><TD class=tabletext vAlign=top align=right>$53. 35</TD><TD class=tabletext vAlign=top align=right>$0. 00</TD><TD class=tabletext vAlign=top align=right>$36. 80</TD></TR><TR><TD class=tabletext colSpan=4>Electrical - Chassis electrical - Senders - Fuel gauge sending unit

FUEL GAUGE SENDING UNIT, All Models, Diesel Engine 2000 - 2002
</TD></TR></TBODY></TABLE>

 

[towner]

I bought a new sending unit about two months ago and damned if the gauge didn't start working the next day. I probably just screwed myself but think its pretty funny

 

[Joe G.]

A bad sending unit can decide to work for a while because of the way it wears, but it's on the way out. Just in case, there is a connector near the left front cab mount pad that may be corroded and causing your problem. Opening it and cleaning the contacts may fix it. Use some electrical grease to seal it after it's cleaned.

 

[towner]

I'm sure not going to fix anything thats not broken. I don't think a sending unit in a box goes bad.

 

[redram]

I'm sure not going to fix anything thats not broken. I don't think a sending unit in a box goes bad.

It's not always the sending unit (float) that causes the problem.

On my 96, the white metal slotted piece which allows the lower half of the fuel tank module to move, the slot wore a larger groove which would cause the lower portion of the fuel module which the float pivots off of, to become stuck resulting in inaccurate fuel tank readings - even though the float sending unit was working fine.



Attached is a photo showing my damaged 96 tank module (the screws that slide in the metal slot are not installed). Above it is a 98 module which is totally out of plastic and also has different plug wiring, fuel line connections and a different sending unit.

 

[redram]

Here is the photo of the 96 and 98 in tank modules