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2nd Gen Non-Engine/Transmission Fuel tank sender issue and repair

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2nd Gen Non-Engine/Transmission ABS temp bypass

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JKosten

TDR MEMBER
Well I had to drop my tank for a second time. The first time I replaced the sending unit and reinforced the basket. It had whorled out the screws that position the lower section.



This time I was having a 1/4 tank rough start the gauge was not reading correctly all the time.



I thought the draw tube cracked (which is common). I was way off.



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As you can see the entire basket had sheared off from the top. This created all sorts of havoc and explains the running issues I have had for the last few months.



I was lucky enough to grab a tank and 05 CRD Liberty sender from my buddy's 01 truck, as he is going to a fuel cell (and roll cage), about 2 weeks ago. I was already planning on doing the swap but needed to finish some other projects first. The truck had other plans.



Liberty module (spring loaded to hold to bottom of tank)

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Install was fine: the factory 96 fuel line plugged right in after being flexed a little.



The plugs are different. I just took apart the factory plug and used the two wires I need for the sender (Dark Blue w/ Orange (Sender) and Black (Ground)).



96

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Liberty CRD

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The only issue I need to fix still in the sender unit.



The factory gauge is designed to work with a 0 ohm full and 130 ohm empty sender. The Liberty CRD sender is 30 ohm full and 220 Ohm empty.



Right now with a full tank my gauge reads 2/3 and when I get to a half tank it will read empty on gauge.



One option I have is to add a 270 ohm 1w resistor parallel to the sender with will make it 27 ohm full and 121 ohm empty. This will let me at least monitor the bottom end of the tank properly and still utilize the low fuel light.



The other option that I am not sure about, is opening the gauge cluster and replacing the gauge resisters to work completely with the new sender. Since I have not been inside a Dodge cluster yet I am unsure of what I will find.



Has anyone else encountered this before?
 
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