Engine/Transmission (1994 - 1998) Fuel sender repair ?

[PUMPERDUDE]

I'm planning on dropping my tank to repair the POS fuel sending unit that the Dodge boys engineered..... Seems they could have done better Anyway ,I've read the repair notes on the Dodgeram page and plan on going with the P-nut +washer fix. Any more tips on doing this job?Anything to watch out for? According to my trip odo, @600 miles I'll have 5 gallons left in my tank tomorrow eveningToo close for comfort. Hope this is the first and last time I have to do this.

 

[illflem]

I did the fix you're speaking of on a failing sender and it only worked for 6 months. Did the fix on a new sender and it's still working fine 4 years and 100k+ later. If you only want to do the job once my advice is to do it with a new sender, they're only $35 from the dealer. Take your time and follow the service manual instructions for the fuel line quick connects. Once you figure them out they are very easy, get in a hurry and you'll cuss until you break them.

 

[Skydiver]

Hey illflem

Mine is bad also. Are the service manual instructions available online?

Thanks Tim

 

[illflem]

Tim try here http://dodgeram.org/tech/repair/fuel_sender/fuel_sender.htm

 

[LandShark]

PUMPER DUDE : Are you aware that you can replace the sender without dropping the tank? Raising the bed is easier and faster (in my opinion).

 

[Joseph Donnelly]

You might check out my writeup in TDR #32, p. 142.

 

[R.ebel]

Originally posted by LandShark

Raising the bed is easier and faster (in my opinion).

I've done it both ways and raising the bed is the way to go!

 

[PUMPERDUDE]

I'll bomb a new one

I think I'll go that route Bill. I don't want to do this again before the new year. Its a shame you have to put a fix on something brand new from Dodge Never had to do that with Toyota parts.



Landshark... . I would have tried that if I didnt have my toolbox/tank bolted down in there.



I'll check it out Joe-D. Thanks everybody!

 

[CJ Johansson]

I did the fancy machined pin repair and mine's still working after, uh, maybe 3 or 4 years?



I suppose I should make up a bunch of the replacement pins, but, unfortunately, I didn't write down the dimensions and all properly (I lost the sheet of note paper I wrote 'em on) , so I'd need another one to measure. If anyone wants to donate their old scrap sender for the project, I might be able to make a limited number of replacement pins for people who want 'em.



-cj

 

[illflem]

cj, I've got one for you, check your email

 

[PUMPERDUDE]

Got the new sender and yanked the tank today. The little hinge pin wasnt the problem. Sender still worked when raised up and down by hand. My float was shot. Saturated. Looked like it was dipped in acid. Glad I had a new unit to stick in there. Thanks for the info folks.