Engine/Transmission (1994 - 1998) 97 fuel gauge issues.

[case310350]

Have a 97 and just recently the fuel gauge is wrong and moving all over the place. I suspect a ground issue, but need advice on how to trouble shoot this problem

 

[GAmes]

Complete troubleshooting procedures are in the factory service manual, but more often than not the culprit is the float sensor in the tank.

I prefer the paper manual when chasing wires.

http://www.genosgarage.com/product/dfsm97-cd/dodgeram-factory-service-manuals

http://www.genosgarage.com/product/dfsm97-print/dodgeram-factory-service-manuals

 

[GrantP]

I doubt it's a ground issue, it's more likely the sending unit in the tank. The sender uses an arm that scrapes across a circuit board as the fuel level changes (the technical term for that contraption is failing me now). Eventually that circuit board wears out and the gauge goes nuts. I'm guessing your gauge works perfectly when it's completely full right? There is usually very little wear on that part of the board.

I had to replace my sending unit years ago on my 97 and IIRC the part was less than 100 bucks. The tougher part was dropping the tank to pull out the unit.

 

[crabman]

After you have confirmed it is the sending unit in the fuel pump canister, here is a YouTube link on a easy way to replace/repair pump.(lifting bed instead of dropping tank)
https://www.youtube.com/watch?v=XZSPFxthp0k
There are also some old posts here on the TDR with detailed steps in repairing the float arm, but the attached photos do not show up now.

 

[The patriot]

I believe the techie term is Potentiometer. Or some call it a pot.

 

[Missouri Mule]

Do a search on here or google for fuel sender repair. It tells and shows you how repair the sending unit so it will keep working.

 

[fest3er]

Mine had been acting up for years. I tested the resistor plate and found a few dead spots. I solved it without spending any money. How? I put a '^' in the sweep arm. Very gently and very carefully. No sharp bends. The 'V' effectively shortened the arm, thus moving the contact point to a working arc of the resistor. I've now had more than several trouble-free years from the fuel gauge.