Engine/Transmission (1994 - 1998) fuel sender

[SEmerson]

I need to fix my fuel sender. It reads empty most of the time. Is it servicable? Also do I just unscrew the cap that holds the assembly to the tank?

 

[Joe G.]

Read the "fuel tank module" part of this:

http://dieselram.com/ubb/ultimatebb.php?ubb=get_topic;f=45;t=000007

 

[SEmerson]

Thanks good info

 

[hsmith]

Gauge unit is serviceable without replacing the module. We have done several. Requires droping the tank and pulling the module.

 

[SEmerson]

I took it out cleaned it and bent the wipers in. Works good.

 

[Joe G.]

Did you check for wear when the line points in the picture? Also did you check for wear at the top of the hole? If the first place wears the pivot pin will be down in the hole a little bit. The edge of the pin will then wear the hole so the rotating part wobbles. The outter most part of the hole will not be worn but you can see the pivot pin moving around just below the edge of the hole where it undercut the plastic. If there is any wear at that point it will fail again before too long.

 

[SEmerson]

all seemed ok. Just loose wipers form wear. The shaft was pretty good.

 

[Joe G.]

The shaft does not wear. The upper edge of it wears the plastic down in the hole a little. You can't see it unless you notice that the shaft wobbles a little by looking in the hole as you move the plastic part the shaft goes through. The loose wipers are caused by wear on the plastic "shelf" on the back of the rotating plastic part. The wear at that point is hard to see, but it allows the plastic part to lift a little which makes the contact lose and allows the end of the shaft to be down in the hole just a little bit. It took quite a bit of close examination for me to figure out what was going on. I made a replacement shaft that was long enough to extend out the top of the hole which stopped the wobble. Then I bent the contact wipers to insure a good fit. That worked fine. Mine had another problem that made it off by about a quarter of a tank. I gave up fooling around with it at that point and bought a new one.

 

[SEmerson]

It all looked prety tight. I think it will be fine for some time to come. Thanks for all the info

 

[RGuzzo]

1/4 tank which way?

Just wondering as when Im down to a 1/4 tank she starts acting strange like she is running out of fuel. The return line is entered into the aux. in port as the metal elbow on the original has been capped off due to a leak. I thought this was the reason for this,now you have me thinking .

 

[Joe G.]

You may need to pull the fuel tank module to see if there have been any other "improvements". There is a basket on the bottom of the module that is supposed to prevent fuel sloshing around from causing problems. You also may have a hole in the pickup tube or it is loose and flopping around.

 

[TMaki]

i just took mine down to replace the module and when i took the sender out the bottom basket wasnt even attached to the top part

 

[RGuzzo]

thanks gentlemen

Ill take a peak and let you know what I find