Engine/Transmission (1994 - 1998) Fuel sending unit

[JustScott]

Hey guys, About two weeks ago my 98 truck's fuel sending unit appeared to be malfunctioning. When the gauge gets to about 1/4 tank you better find some diesel, because you are empty. This is almost the opposite of my old complaint which was that when the low fuel light came on there was still about 10 gallons in the tank. My local dealer told me that this is just how the fuel gauge in my truck is. What I was wondering is if anyone makes a sending unit that reads more accurately than what I can get from Dodge? I've checked with three part stores and they don't even carry one.

 

[LHastings]

What three part stores did you try? I'm in the same boat. My gauge is inaccurate too. I'm on my third sending and it is getting worse. It is now 17 gallons off, then it hit empty I still have alot of fuel left but I don't trust it with the fear of it might sprung a leak.

 

[JustScott]

I tried Oreily's, Auto zone, and Advanced. None of them had the part and recomended I go to Dodge. I called them, and it was a $65 for a new sending unit. I made one more call to a local Federated Auto parts store. They have a universal type sending unit for $17. He said it was just a two wire hook up. I'm not sure what to expect when I get the tank down, but I'm thinking about buying both sending units, dropping the tank and using the one from Federated if I can, since I know I don't like the ones from Dodge. I too had two other sending units replaced while under warranty.

 

[JKouzez]

i think on dodgeram.org there is an explanation of how to fix this problem for close to nothing.

 

[Dave Remillard]

There is a way to repair sending unit, however I have the link on my PC at home. I'll try to remember to log on tonight and post it for you. Perhaps someone else will chime in prior with the information. Basically you take the unit out, add a new spring and washer, reinstall and drive on with what sems to be a fairely reliable sending unit. I repaired mine several months ago and it's been fine. I've read where others have been going on for years after the repair and srtill no problems. You might also try a search and see what you can come with. I. M. H. O. I would shy away from some after market thing in my fuel tank. I have visions of some little piece coming apart and fouling something that could be much more costly to repair.

 

[JustScott]

Thanks JKOUZEZ found the fix I will give it a try.

 

[JustScott]

Hey Dave, Found some good pictures and instructions for the fix. (Thanks JKOUZEZ) The universal sender I looked at doesn't look like it would have worked anyway. I appreciate the help guys.

 

[Andy Redmond]

Scott:



assure that you source the correct sender from Dodge.



Carter (Fedeal mogul makes it, but it is not sold thru Federal Mogul channels to the aftermarket, read go to Dodge).



The module has changed somewhat (94-97's have a 100-140 ohm sender)

98-02's use the 240 ohm sender.



Get the old style and your gauge will not accurately report the fuel in the tank.



Take a perusal at the FSM, it will give guidance on testing things while the tank is dropped.



Pay the piper and maybe do the mod that's been discussed to the new or existing sender, then no need frantic cell phone calls for a tight lip to bring you some fuel in a can or risk pumping dyed diesel in the truck and getting popped by the Feds (ag aux tank).



Good luck

Andy

 

[vova]

Thanks JKOUZEZ found the fix I will give it a try.

So what's the fix. Post a link since I have the same problem...

 

[SGastelu]

99 fuel pickup sending uni

I got a 99 fuel pickup off of ebay but it doesnt work on my 94. Anyone interested they can have it for what i paid $50. Its all the parts from inside the tank... rubber gasket. . sending unit... pickups... etc...

 

[JustScott]

Here's the address to Huey Conway's fix. http://dodgeram.org/tech/repair/fuel_sender/Huey_C-sender.htm

 

[JustScott]

Andy, thanks for the advice. I would have loved to have made a frantic cell phone call, but I had left it in my wife's SUV I had been driving earlier in the day. Had to walk to a parts store buy a gas (fuel) can and then walk past several gas stations (in the rain) untill I found one that had diesel. I was in a part of town I wasn't familiar with and couldn't find anyone to give me a ride. A nice guy at the gas station gave me ride back to my truck.

 

[JustScott]

Just an update. I dropped the tank and removed the sender. Couldn't really find anything wrong with it at first. Then I noticed the contact points that would give the lower fuel ratings looked a little discolored. I cleaned off some kind of dark residue with a rag. Pluged it in without the fuel tank and held the arm at the top and bottom positions, and the gauge worked fine. My sending unit appears to be a newer version of the one that I had found the quick fix for. There is very little play in the float arm housing. I think I am going to try to find some sort of shim to tighten it up anyway.

 

[John R]

Bending the float arm seems the best solution to match the gage with the gallons in the tank.

 

[JKouzez]

no problem let me know if it works because i would llike to fix mine.