Engine/Transmission (1994 - 1998) Fuel Sending Unit Repair Question

[Northrunner]

What is the best fix for the faulty fuel sending unit in the fuel tank? I'm sick of listening to my "low fuel" alarm coming on sporadically while there is plenty of fuel. I've heard that a new one from the Dealer is still the same piece of junk.

 

[DProehl]

I listened to that low fuel alarm for two years before I pulled the tank and fixed mine. I wish I had taken pictures of my fix but it was pretty simple. I welded a small arm on the bridge on the sending unit and put a small spring under it to force more pressure on the reostat arm so it didn't break contact. If you drop your tank, pull the sender and look at it it is pretty easy to figure out whats wrong and how to fix it, Good luck with your project.

 

[Joe G.]

Look at the 2nd post in this thread: https://www.turbodieselregister.com...ions/188123-anatomy-fuel-tank-gauge-unit.html

 

[Howard Durand]

An excellent post. The pictures are outstanding. The device itself appears to be well designed and of good quality construction.

Are the floats protected by any means that would prevent stress to the assembly when the fuel is sloshing around in the tank? My truck has over

120K miles and never any problem with the fuel gauge but it has never been used in Off road situations. Almost 100% paved roads.

 

[Joe G.]

I think the rest of it is all stock. Kirk's simple fix is all that he said he did to his fuel module. My fuel guage sending unit had over 200K miles on it when it failed. The new one I bought from Dodge looks to be almost the same. It does look a little bit better made in some places but not much. So far so good with it.