Fuel Gauge Sending Unit

[MAYoung]

Gentlemen:

My fuel gauge has become erratic over the last several years; if I keep the tank full, the gauge reads correctly. As soon as it passes the 1/2 full point, the gauge can flip to zero then back to the tank amount. I understand that it is a worn sending unit.

Here's the problem: Dodge no longer makes a replacement part for this sending unit. Their fix is to sell the entire pump that fits into fuel tank. That fix would be ok with me but I already have the truck set up with the DDRP and the fuel system is working well so I am reluctant to change it out. (Installing the pump in the tank requires a change in wiring connections up at the engine block where the original Carter pump went.)

My question is this: Is there some other type of fix for the fuel sending unit? (I understand that the resistance contact wears down so that the electrical signal become problematic.) Some other non-OEM part? An alternative part or "hack?"

Failing that, can I install a new pump in the tank and leave the DDRP installed? What problems will I encounter?

Thanks for your input.

Mark Young

 

[NIsaacs]

They appear to be available:

https://r.search.yahoo.com/cbclk2/d...AMx?p=1998+dodge+2500+fuel+gauge+sending+unit

 

[NIsaacs]

I just ordered this one, but it appears to not fit your truck.
https://www.genosgarage.com/product/04897669ab/fuel-system-accessories-replacement-parts

 

[mwilson]

I have checked on this before, there were two different modules used hence there are two different sending unit part numbers as I recall on the 2nd Gens.

 

[NIsaacs]

I have checked on this before, there were two different modules used hence there are two different sending unit part numbers as I recall on the 2nd Gens.

Thanks Mike, that is what I found but it is still somewhat confusing. Genos shows a module for 98-02, yet the sender is only 00-02. Then they show one for 96-97, no clue what happened on the 94-95.

 

[JMcCoy]

I was able to repair mine. That was about five years ago and it's still good.

 

[mwilson]

Only safe way is to look it up by the VIN. Then there will be the part number for the original module (with a sender listed) and replacement module (with a different sender listed).
Order both senders making sure you can return the one you don’t use.
If the module had been replaced at some point this will cover all the bases...

 

[mothertrucker]

I have replaced the sending unit on my '97 3500 three times now over the years & each time it only lasted a few years before going dead again.
Finally gave up on replacing it with the same problematic unit.

I now use the trip meter as my fuel gauge.
{don't forget to reset it to zero each time you fuel up }.

 

[fest3er]

Look at the arm that sweeps across the resistor plate. Using some gentle and careful bending, you can shorten that arm to make it sweep across a different arc. I did that to mine 5-8 years ago (I put a 'v' in the arm); the gauge has been steady ever since.

 

[DavidC]

I think it was Vulcan a few years ago that offered replacement modules but I do not see them on the site. You could call them and inquire, maybe they can help.

Dave

 

[MAYoung]

Responders are correct in this instance. There are two different sending units for the 24 valve fuel gauge. You can still get the replacement part for the sending unit for the in-tank pump; the earlier 24v sending units (no pump in tank) are no longer available from Chrysler. In fact, my dealer located the part at Chrysler several months ago only to be informed that the part was no longer available. It must have been the last one since they were able to get the part only weeks before.

In doing online searches, I find many parts that appear to be new sending units but upon closer examination, they are sending units for the in-tank pump. Dang.

 

[NIsaacs]

In doing online searches, I find many parts that appear to be new sending units but upon closer examination, they are sending units for the in-tank pump. Dang.

Did you read the fine print on the Geno's link I posted? It says it is NOT for the in tank pump style module. I hope so because I ordered it, lol.

Edit: I keep forgetting you have a '98, so it may or may not work....

 

[KATOOM]

I just replaced mine... As exciting as it was in the beginning, I soon realized that I wasnt actually getting a few hundred miles more per tank just because my fuel gauge wasnt moving. So I've been driving by the odometer for the past few years.

I wonder what eats these Dodge diesel rheostats? A problem I've never experienced on any other vehicle.

 

[BoeingDiesel]

I have replaced the sending unit on my '97 3500 three times now over the years & each time it only lasted a few years before going dead again.
Finally gave up on replacing it with the same problematic unit.

I now use the trip meter as my fuel gauge.
{don't forget to reset it to zero each time you fuel up }.

I did the same several years back on my '99 and just reset the trip ODO on every fill up...but then, I have never pushed the truck much beyond 300 miles per tank.

 

[DavidC]

Some other things to think about. These are many years old but I kept them for the inevitable.

https://www.turbodieselregister.com/threads/fuel-sender-capacitance-type-install-notes.199933/

 

[DavidC]

Sad part of that file is no pictures. If I open it from the saved file on my computer it opens in internet explorer with all the pictures

 

[KATOOM]

No pictures... I've tried Firefox and Explorer. Too bad because this looks like an option for some people but without the pictures its hard to follow. Wonder if Barry still has the pictures.

 

[DavidC]

I was just going to message him. If there was a way to get that file from my computer posted here, I just haven't found a way to do it

 

[KATOOM]

Save the picture from your file and post them on the forum. Or if you want to go through the effort, copy the old thread and repost the pictures back into it.

 

[DavidC]

I just messaged Barry with this link, we will see