Engine/Transmission (1994 - 1998) Fuel gauge reading way off

[ThomG]

My 96 fuel gauge when reading a frogs hair under 1/4 full will be in reality almost empty. Had a new sending unit installed last Oct and it still reads the same. I first noticed a problem around 2002 when the original [ I think] started reading weird, had dealer install a new one then. This was slightly better, but it would still take 31-32 gallons at 1/8 tank on a couple of occasions I let it get that low. I normally will be looking to fill at just under 1/2 but sometimes its' not convenient. Can some thing in the gauge or instrument cluster be bad? I talked to dealer service mgr. and didn't get any help. Thanks for your ideas.
ThomG

 

[hsmith]

I have repaired quite a few of these, mine included, with the same issues and it is always the sender.

 

[fest3er]

I have repaired quite a few of these, mine included, with the same issues and it is always the sender.

Pull the in-tank module, then remove and disassemble the sender. Remove the 'sweep arm' and modify it.

Stock, it is generally like "------------". Put three gentle (definitely not sharp) bends in it so it sort-of resembles "-----v-----". (It's hard to show with ASCII ). Basically:

• Near the middle but ¼" closer to the pivot, bend down 5°.
• ½ closer to contact, bend down 5°.
• Midway between the two bends, bend up 10°.

Make sure the bends are gentle and round (1-2mm radius) and make them slowly; you don't want to break or weaken the arm. The result is the contact will be about 1-2mm closer to the pivot. This change moves the contact onto a fresh part of the resistor system. You might even polish the contact point with a bit of crocus cloth.

I did this to mine a couple years ago. The gauge has been steady and accurate since. It hadn't worked right for at least 10 years.

 

[ThomG]

Many Thanks for the input. Now, do I really want to drop tank, or raise bed to give this a try, or deal with it??? Oh yeah, I apologize for putting this in the wrong site.
Thanks again
ThomG

 

[MLee]

An other suggestion while you have it apart. Look at the float, does it show signs of wear? from making contact with the top of the tank? mine did. So I coated it with Epoxy, made sure that the float moved freely on the arm when dry. This will protect it from wearing away and becoming saturated with fuel. I also thought that it might change the weight of the float and give a bad reading. It did not. When you clean the lift pump screen, the black stuff that's in the screen is the residue from the float wearing away. No suggestion on the bed thing, your choice.
I also have a fix on the WIF connector, cause they wind up and break the wires.

 

[GAmes]

Can some thing in the gauge or instrument cluster be bad?

Yes. Full troubleshooting procedures are in the manual.

http://www.genosgarage.com/1996-DOD...MANUAL/productinfo/DFSM96_PRINT/#.U3VL6XYjl0g

 

[Jeff L]

Me too >sigh<. Runnin' 'er towards empty and gettin' ready to get after it, 'cause it drives me NUTS.