Fuel Sender Repair Kit

[LDusky]

Fuel sender going south. If someone has a bill of material or a kit I sure would be interested. Someone had a repair kit available for a couple of bucks but that goes back aways and I can't the lead.

 

[GFreshour]

Fuel gauge fix

I got this info from this board previously, I have not tried it yet:



Your fuel gauge problem is due to the sending unit in the tank going bad. Don't

spend the money to buy a new one though. The fix is so easy and cheap (cost49 cents).

Here's how you do it. Following your manual to get the fuel sending unit out of

the tank. This is the hardest part since the tank straps are very difficult to get

off and the "Big Platic Nut" on top of the sending unit can be a bear.

Once the unit is out of the tank (it's big by the way) find were the float hinge

is. You will find an electronic brush that moves along a variable resistor. The

problem is that the plastic bushing has worn out and allows the brush to move

away from the resistor (infinite resistance and therefore the light on the dash

lights up).

Remove the pin and the float hinge joint and drill the hole slightly oversize.

Replace the pin with a small bolt and screw. Make sure to use a self locking

nut. Tighten the nut only enough to prevent freeplay in the joint but so much

that it restricts movement of the float.

I did this to mine about a year ago and its still working fine.





Welcome to the group, My 96 did the same thing on the temp, outside temp was 55 deg and the gauge barely moved at all new thermostat fixed it. The

fuel gauge prob is considered normal on these trucks, if you have one that

works correctly you are in the minority. Easy way to replace it is to remove all

the bed bolts except the back 2 and tilt the front up for clearance dont forget

fuel filler and wiring disconnect. way easier than dropping tank.

 

[redram]

Re: Fuel gauge fix

Originally posted by GFreshour

I got this info from this board previously, I have not tried it yet:



Your fuel gauge problem is due to the sending unit in the tank going bad. Don't

spend the money to buy a new one though. The fix is so easy and cheap (cost49 cents).



This is the most common problem but NOT ALWAYS the problem.

My '96 stopped working after 2 years (but outside of the 36K warranty) due to the white metal slider piece hanging up. When this happens, it changes the pivot elevation of the fuel float causing an inaccurate and non-repeatable readings as it would catch high, then low, etc.



I have run almost 4 years (90K) without a functional guage. Repaired the slots once but it is now too worn to work at all. Will have to replace the entire unit unless someone has the white metal top piece of the intank module as a spare... ...



Running empty is no problem because I have a good idea of the fuel mileag. Running various loads makes it interesting to keep track of the amount of fuel remaining.

 

[CumminsAholic]

You could try here. There's 3 links.

http://dodgeram.org/tech/repair/index.html#wiring

Corey

 

[rono]

My sending unit is about gone at 35K. Only goes down to about 3/4 and stop there. I called the dealer and ask the serv. advisor to see if they had them in stock and he said he thought so because they replace a lot of them. They have one in stock so I'll be taking mine in tomorrow. My '97 had 2 replaced.



Ron