Fuel sending unit bad--4th time

[BLACKRAM]

I have 51,700 miles on my 99 Ram, and the 4th sending unit just went bad. The fuel reads full regardless of the actual quantity in the tank. The only thing I can think is causing this is the addition of Power Service Cetane boost. On previous repairs, I noted the deterioration of the electrical contacts on the sending unit. This most recent failure is only 2500 miles since the last one.



Has anyone else had this problem? Any solutions? Any aftermarket parts that may be superior?



Any help is welcome.

 

[illflem]

I doubt if Power Service is causing your problem unless you are adding massive overdoses, it doesn't take much. I've heard of folks like you that have had repeated sender failures finally tracing the problem back to a faulty PCM. Talking the dealer into replacing it might be a tough proposition depending on your dealer. As I understand it a problem that isn't fixed under warranty and is documented will continue to be warranted. I knew one fellow who sold his truck back under lemon law protection just because of reoccurring sender failure. If you pay $30k+ for a rig it should work right.

 

[SlyBones]

Well this may not be relavent to your situation, but here goes.



when I got my truck, used from dealer, the fuel gauge did not work. I told them I wanted it fixed as part of the deal. They agreed. Took it back about a week later to have the work done. They replaced the sender and the module in the tank, the whole works. About $500 bill if I paid. -- During the week I searched the internet some and found that this was indeed a common problem. And that many guys just replace the $50 sender and thats it. -- Anyways when I picked up the truck I asked why they did the $500 route and not the $50 route. After all it was coming out of their pocket. They told me that if they replaced just the sender I would be back in 6 mo, complaining about it not working again. Dodge has updated the parts, and when they replace the entire thing they dont come back. So far 1. 5 years and still works.

 

[tcourse]

Agree

Slybones, I've also had a few senders replaced. Went in to dealer a few weeks ago with a list, including fuel gauge.

This time they replaced module. I wondered why. Thanks for the enlightenment.



TC

 

[lschultz]

My son has a 99 with about 90000 and no problems with fuel sender---YET. It went out on my 2000 and let me run out of fuel. They replaced the sending unit and the module. It has about 46000 now and this happened when it had around 20000. So far so good but it makes you wonder when it's gonna happen again.

 

[dodger22]

There was a post on this not long ago if I recall. The sender can go bad if you use the high volume pumps that the truckers use. The trick was not to squeeze the lever to maximum.



Just a thought... ... .



Richard

 

[BCFAST]

Why trust it?

Forgive me guys, but why do you need to know how much fuel is on board? Dont you "re-zero" your odo at each fill-up? We all have a pretty good idea of our own truck's milage capability with various load configurations... if you average about 20mpg, and you have 30gal usable, you should start thinking about fuel somewhere around 500 miles on the odo... . it aint rocket science!~ But I agree that since your NEW truck costs the same as a new MB, the freakin thing should work right!

 

[BLACKRAM]

Dodger22, now that you mention it, the gauge failed after filling at a high volume pump!

 

[illflem]

I'm still trying to figure out the fast filling failure theory, heard it many times. Can't see how it would make a difference since the sender is enclosed in the module. Some senders will get stuck on full after filling but that is only because the tank is full and the sender is physically stuck upward.

 

[BLACKRAM]

Update on the fix.



Dealer completed repair today by replacing the entire module, instead of just the sending unit. The service writer found a TSB that said the entire unit must be replaced or it will quickly fail again. They had no prior reports of the method nor size of refueling pump affecting the outcome (normal size vs. large semi truck pump).



I was NOT charged for the repair. With 52,000 miles, that is a good deal. I feel part of this is due to the fact that I sometimes tip the tech $10-20 for work, and have sent letters to the dealer, complementing his service department. I have spent $50-60 on tips, yet received a lot more in return. The module is about $350 for just the part. They have not "flagged" my truck with D/C as to it being modified, and stop work on other vehicles to take care of mine first. So before you go cussin' out the service people, think about what they want out of the deal. Do you think they want a hassle? Or do they want to be treated the same as you?

 

[John]

I don't think so

I have a hard time believing the replacement of the entire fuel module will correct the problem. I think careful installation of the fuel sending unit within the module (after carefully checking it with a multi-meter) and a subsequent check after the module is installed in the tank should easily suffice. The reason I say this is, exclusive of the fuel sender there's nothing within the module that could cause the sender itself to go bad.

 

[MikeR]

I agree with John. I can't see how replacing the entire module would make any difference. I checked and checked again when replacing mine. Upon inspecting the failed sender, I can see how these things fail, but wether the entire module was replaced, the same contact strip/spring is still the culprit.



About the sender staying on full... .

The float rides very close to the tank wall. When I installed mine I ended up hitting the tank wall, and what happened was, after filling up, the float was jammed against the wall and stuck on full. It took a couple of tank fulls for me to verify what went wrong, so I loosened up the tank ring and shifted the module counter-clockwise and I heard the float drop down into the fuel. Problem fixed.



-Mike

 

[Hummin Cummins]

I too had fuel sending unit problems when i bought the truck used. Mine was reading empty all the time. Replaced the sending unit, 50$, wound up the rivet holding the float onto the rheostat was worn not allowing contact. After replacing i found a thread on tdr..... replace the rivet with a machine screw and nylon locknut to tighten up where the float assy. hinges.

Oh well I'll remember this for next time