2nd Gen Non-Engine/Transmission Fuel tank module...what happened?

[jhurst]

Well the fuel gauge quit working on my '99 so I bought a new sender. Lifted the bed Saturday and pulled the module out of the tank to find that it is broken and replacing the sender isnt going to do the job. So I took some pictures of the module and slapped it all back together.

All four of the "posts" towards the top of the module are broken. What could have caused this? Vibratation weakened and finally broke it off? Anyone else have this happen?

Sure dont want to have to pay for a new module. Buy a new one or head to the salvage yard?



Going to try and post the pics...



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Justin H

 

[Ted Constantine]

Justin did it just stop working all of a sudden?? or did you see a change over time and eventual loss of function? Mine seems to be showing more fuel than is in the tank and has been getting worse over the last year. It went from showing less fuel than was inteh tank a year and a half ago to now i am out of fuel with a quarter on the gauge. I am procrastinating dealing with it as I hate, HATE the dealer. I have never seen one that completely blew apart like yours though.

Ted

 

[jhurst]

It just started reading low about two weeks ago. With a full tank, it would show I had 5/8. So I figured it was the sender. After I pulled it then put it back it started working again for about 5 miles. My guess is it started reading low because it was sitting wrong in the tank, then when I put it back in, it was straight again until if worked itself back out of position.



I seem to remember reading a post quite awhile back about vibratation causing the metal to weaken and fail but could not find the post anywhere... . maybe my imagination.



Justin H

 

[redram]

Mine did not break like yours but wore the slots out in the metal that allows the bottom half to move relative to the top half. This would make the unit stick in the wrong position, changing the pivot point for the fuel sending unit float, causing inaccurate and inconsistent fuel level readings.



Most everyone else seems to just have sending unit problems. Welcome to my club of 'fuel module' woes.

Been using the trip odometer for years as I too do not want to spend hundreds for a crappy design that may fail again in several thousand miles.

 

[jhurst]

redram,



I did notice that the slots in the metal had a spot on each side that was almost worn through like you said. If it hadn't broken apart at the top, then I would have been in the same boat as you pretty quick.



Justin H

 

[jhurst]

Does anyone know what year models are interchangable for a '99 2500? Possibly the 1500 gassers or 3500?



Thanks



Justin H

 

[Bigramguy]

As far as I know,all the diesel tank units are the same for the 2500 and 3500's



The gasser units will not work,as they have the electric pump mounted in the fuel unit.



Mine quit working back in 98. Finallyu had to drop the tank,as the fuel lines coming out the top rusted out. I repaired the sending unit pivot with a nut,bolt and wave washer and it's been fine ever since.



Not sure what to do with the broken fuel module,but I'm sure you could rig jig it together somehow. What have you got to lose.

 

[dlmartin]

91 Fuel tank Module

The fuel tank module broke loose at the attachment tangs and fell into the tank pulling the fuel supply hose with it, so I'm DOA. Scared to call dealer tomorrow to find out replacement module either worth 1/2 what truck is worth or not available. Does anyone know cost of new module or if other years will work? Is metal cage available separatedly? Any salvage yard to recomend for this?

 

[gary12744]

I just purchased a 97 3500 with gauge problems. I went to the local dealer and purchased a new sender, list price was $61. 54 but I asked for a 20% discount and he gave it to me. Never been there before but I will go back. Any way he priced a new module, it ran about $350. 00 ouch!!! I hope when I drop my tank that I don't find the module problem.

 

[jhurst]

More than likely its your sender... but you never know!



If you do have to replace the whole module, try a want ad in the classifieds on this site. I put one up and had someone reply in about two days with one from a salvage truck for $50.



Good luck!!



Justin H

 

[TKeeler]

I have a 98. 5 and my fuel gauge has started acting up full time now. 3 or 4 years ago it stuck a couple of times but had been working fine since. I as well have been using the trip meter but my wife drives the truck some as well and doesn't like doing that. When I fill up it goes to full just fine but after a hundred miles or so it will sometimes slowly drop to empty, usually when I shut it off and start it the next time. As I drive it very slowly goes back up but never back to the actual fuel level in the tank. I hate trial and error repairs... does this sound like a sender problem or the module? Not real keen on spending $350 for a module if I don't need it.



Thanks

 

[Kalaehina]

jhurst, that is exactly how my module looked for 4 years, all mounts broken except 1. And they were all broken at different points, it was also worn down the sleeve screws. I dropped my tank many times and just repositioned it everytime. Finally the last mount broke, module fell over, fuel gauge wire pulled out, no fuel reading, and the pick up hose couldn't suck from the lower part of the tank so I "ran out" of fuel at like 290 miles on a tank. Not fun at all, good thing I had a 5 gallon can with me, just because fuel tank problems was the issue at the time. Anyway, I made new mounts, riveted everything, and so far (3 months) I have good fuel readings and full use of the tank. We'll see how long my mounts last.

 

[Bart]

I just came back from a turn around trip from So. Calif to Indiana. I noticed that the gauge didn't read full after a fuel ups and then at the end of the trip the d(*^*%^# gauge read no fuel when I turn the ignition on. I cycled it several times and it started working. Several minutes later it read full and I knew it wasn't full. So I filled it up (into the neck) and it only showed half. As I drove it worked up to 5/8 before workin' it's way back down to empty, and I hadn't driven that far. I filled the tank again and it only took 10 gals. :{ So I'm surfin' trying to find a cure