2nd Gen Non-Engine/Transmission Fuel Sending Unit/Gauges

[DWalters]

Well I think my fuel sending unit is bad. My fuel gauge is stuck at 0 and doesn't move at all. I also have the low fuel light on. So my question is how hard is it to drop the tank to fix this. Is it a pretty simple and quick job and also where should I order the new one from.



My next question is that I am ready to throw some gauges on my truck. I know that I want the Fuel press, EGT, and Boost. I am thinking of Westech, DI pricol, or ISSPRO. I was just wondering which ones are the easiest to put in and if I would be able to do it myself.



Thanks, Drew

 

[JCreese]

Drew,



Just replaced my fuel sender last weekend and decided to drop the tank, however, if you do a search for this topic you'll get lots of opinions and advice on droppping the tank vs. lifting or sliding back the bed. I actually just lowered the aft end of tank by removing the aft strap and loosening the forward strap after unconnecting the filler and vent tubes. Still used a floor jack to lower aft end, but only had about 5 gallons in tank.



Your search will turn up many problems and fixes. As for my repair, I ordered a replacement sending unit (about $50) from Dodge dealer (only source), as that's what I suspected as the problem. I was also looking for a problem I read about on one of my searches that involves the module "sliding" section wearing grooves into the metal track it rides on. Sure enough, that's what I found. I filed the grooves down smooth and then placed a large (about 1" square) thin piece of teflon (could use large teflon washer) behind the screws that ride in the slots of the module. It seemed to slide now with no problems, but time will tell (better than going right to a new $400 module).



As for the fuel sender, it looked fine, but I already prepped the new one (as described in the searches I read), so I installed it to insure a good fix and not kick myself later (poor design almost guarantees failure sooner or later).



RESULTS: Works just Like new!



As I mentioned do a search for "Fuel sender repair" and you'll get all the info you need. I printed out a few posts that sounded like my problem and had them handy when I dropped the tank.



Hope this helps,

Jim

 

[JCreese]

Drew,



One more thing. On last reply I jumped right into my fix of my module and sender. Obviously you'll need to rule out your guage first, and a search for your specific problem will help with that too.



Good luck!

Jim

 

[CMckee]

i just did mine as well a couple of weeks ago. i was getting goofy readings, the top 3/4 was acutally only half a tank. if i had a load on the top 3/4 was about a 1/4 empty tell that doesn't make you nervous to see the gauge fall like a rock and only going about 200 miles. anyhow, i dropped the whole tank using a floor jack, made sure to run the tank almost empty,the hardest part was getting the "quick connect" fuel lines off. i ended up just cutting the lines and replacing them with rubber lines and clamps. the wiper arm was pretty much wore out on the old unit, the new one works great 1/2 tank is 1/2 tank! it was $97 cdn dealer only.

 

[rkressg]

I had the same thing happen. I thought the sending unit was bad, so I dropped the tank. Much to my surprise, I found that the float actually worked its way off the sending unit. The float was floating around in the tank, and the sending unit level was at hanging at the bottom of the tank. I still replaced the part because I bought a new sending unit, but I could have just reassembled it and it would have worked.



For gauges, get ISSPRO boost and fuel pressure. They are mechanical, so you don't have to worry about sending unit issues, and get the ones with a white needle, so you can read them easily at night. I personally run a Hewett pyrometer for my EGTs.

-Rich

 

[blackram99]

I had to replace my whole unit, cause it started leaking and it was were the lines came out of the sending unit... ... Costed me $332. 81 from DC. list price was $417+tax... friend of mine works for dodge and got it at his price... . I slid the bed back to work on mine, took about 4hrs. I could do it now in 2hrs "TOPS" not a hard job at all..... need any info on doing it that way let me know I can tell u step by step and what tools u need all of it is fresh to me I just did it 3-18-05 just send me an e-mail... would be gladd to help..... Oh yea one more thing, the clips that hold the fuel lines on... are fragile be careful takeing them off... (that was the hardest part of my whole job) trying not to break them. You also have to tilt the unit when u bring it out of the tank and put it back in to keep from damaging it... .

 

[dodge cummins]

the heck with fixing it. save the money for bombing. i just fill her up every 525 miles.

 

[DWalters]

thanks guys



Drew

 

[TFrench]

Fuel/Sending Unit

BlackRam99,

My sending unit ('97) is leaking/spurting at the return line elbow. I've been trying to get the fuel lines off but I don't seem to have much movement in any of the fuel line clips. I suspect part of the problem may be that there is lots of grit and scale in the fuel connector "windows"/openings. I've propped the bed up on the driver's side about 8" and can just about get under there... but old eyes, glasses and diesel fumes are making it hard to see! I'm assuming I want to pinch the tabs toward the tubes on the outboard-side of the connector vs in the two "windows" on each connector. If so, I assume the plastic tabs stay with the tubes when the lines are pulled off . Can you confirm that I understand this right or elaborate a bit? I really need to get this assembly out and cleaned up to know if it is worth repairing (if possible) and only replacing the sender or if I need to replace ithe entire assembly. Thanks much in advance for any advice/instructions!

Tim

 

[Andy Redmond]

Tim:



Yes the plastic connectors stay on the lines inserted or removed. Squeeze both sides gently and wiggle the line off. Carefully use a dental pick/o-ring pick to dislodge the red elect. connector lock, then depress the connector and remove it.



If you let the back of the tank down a bit, it will give you some elbow room.



I imagine the road salt may have perforated your metal lines where they go into the module. Lets hope not. .



Carter typically manu. the sending unit and tank module. Carter does not sell the sending unit ala carte. Find a Federal Mogul auto parts vendor and your good to go. Send me a PM if you have problems locating parts. Go to the dealer for the sender.



Good luck

Andy