Bad Fuel Sending Unit?

[Ted W. Hazen]

I filled my tank up today and went about my business. I had driven about 30 miles and everything was normal. When I started my truck up to head for home my fuel gauge registered completely empty and my fuel warning light was on. Does this sound like my sending unit is gone. I know there are a lot of posts but don't remember what symptoms were exhibited when the unit went. Are there any other sources for the units other than DC?

 

[CumminsAholic]

I think that usually (like mine) they read low when you're actually not that low. Mine will say I'm out (past the last line) when I have 15 gallons left. Some could just stop working though. I don't think there's any other sorces than DC or yourself. Here's a link with some instructions. http://dodgeram.org/tech/repair/index.html#wiring The new part you need from dodge is like $30 I think. You don't need the whole module only the sending unit. I can't seem to find the part #. Maybe something came unplugged or is momentarily stuck beings as it just quit.

Corey

 

[Macmc01]

Mine would work until it got to 3/4 tank then it would read what it wanted, E to F then waiver at 1/2 but just under 3/4 tank it would go to E and stay there. The only the Dummy Light wouldn't light up.



The only time it did light up was when I was almost out it started surging and wouldn't idle. once I filled it up It was Ok.



First I would check the connectors and maybe smack the tank. It should go back to full when you fill up. I haven't heard of one just completely dying but it could happen. (you know who made it )



Hope this helps



Mac

 

[Vaman]

Long, long history of bad sending units...

 

[Ted W. Hazen]

Just a little clarification on what the fuel gauge was reading. It wasn't reading just low it was in the position it goes to when the ignition is shut off and as stated above the fuel warning light was on. The tank probably had 33 plus gallons in it as I had only driven 25 miles since filling up. No prior hint of any problem.

 

[illflem]

Ted, I think your sender might be ok, you have a bad connection somewhere. Unplug the connecter close to the tank and short the wires together, if it stays on E you have a bad connection somewhere between the tank and gauge. If it reads F the sender is bad. There are some sharp self tapping screws in the sender/pickup module, one may have worn a hole thru the float, it filled with fuel and it sunk. Usually when the sender fails it reads incorrectly, not just empty.

 

[BBrodin]

Ted, my 98 has the same problem. Doesn't matter how much fuel is in the tank.

I will start the truck and the gauge shows empty. This doesn't happen all the time.

I shut it off and restart it and the gauge works properly.



I'm taking mine in to have the sending unit replaced.

 

[cumminsgetme]

Ted, my truck showed the same symptoms 4yrs ago. Sending unit was the culprit.

 

[John]

I experienced the erratic fuel gauge reading exactly one time... at approximately 1k mi. (on my '98. 5). My Ram was almost completely full of fuel when it happened... upon starting my 24v the fuel gauge dropped to Empty, triggering the Low Fuel warning light. Although I can't remember if I turned off the engine or not, the problem did go away... never to return (for more 59. 5 k mi. ). Just to be on the safe side I installed a new sending unit when I installed my Transfer Flow 54 gal. replacement tank recently.

 

[Ted W. Hazen]

Thank you all who have responded to my post. I followed illflems advice and disconnected connection at the tank and shorted out two middle wires. Fuel gauge read full. With jumper removed gauge read empty. According to Manual my sender unit needs to be replaced. Now I have to wait until my full tank is run down. I can't lift bed as I have 5th wheel hitch with all the bracing underneath. Tanks again.

 

[Steve G]

I filled up this week and mine was showing 1/4 tank and I put 32 gallons in. I think there's a lot of these going south.



Steve

 

[KYOUNG]

SENDING UNIT

I replaced my sending unit 2yrs ago. It was fairly easy. On a4x4 you can get inside the fender well and unhook the fuel lines(clips on fuel lines) ,loosen the lock ring and unhook filler hose,unplug wires. I put an adjustable tie down strap around the back of the tank to hold it up loosely, put a floorjack under the front of tank, tookthe mount straps off and lowered front down enough to pull sending unit canister out. While your at it clean screen and replace lockring seal. Carefully remove sending unit from tank so you don't bend float arm, change faulty unit and reassemble

I have also had the rear fuel tank mount band break at the factory weld

 

[Ted W. Hazen]

Boy, I feel like I'm beating a dead horse. I've removed the sending unit housing and inspecting the unit I noticed a wear spot about eight inches down from where the fuel return line enters the top of the housing. On closer inspection I discovered a small pin hole in the wear spot. It appears that when the unit was assembled the bottom of this line was not placed in a guide hole near the bottom of ther housing causing the line to move against a sharp edge. I don't feel this hole is of any consequence as the return fuel just exits the end of the line near the filter at the bottom of the housing. I didn't want to reassemble the sending unit and find out later my logic was flawed.

 

[RKelly]

had a bad sending unit in my '99

dealer repaired it under warranty. no problems since.

ray