My truck, since new, has had an ongoing fuel gauge issue. Warranty replaced it 3-4 times. Warranty ran out years ago, but occasionally it will freeze at full. The second to last time it got stuck at full, it started registering fuel level after driving on some bumpy, rutty forest roads. It froze again at full just before the new year, so yesterday, I took it off road to try some bumps and sure enough, it started working again. Anyone have any ideas what would cause it to stick and then get jarred loose by rough roads? Thanks.

If the fuel basket is not aligned properly the float could be hanging up on the side of the tank.

Guess the only way to check that is to pull the tank module? How would I know if it's not aligned properly? Will it be obvious?

I would try loosing the ring that keeps the basket in place then turn the basket a little and rechecking to see if this helps.

next time it gets stuck, smack the inboard side of the tank at the basket and see if that shakes it loose.the float on my 02 is on the inboard side. Might work, never had to try it myself.

I just had my fuel module out and can see what Dripley is talking about. You want to turn it a little counter clockwise.Also check the wires connection on the top of the tank. Mine doesn't click in or lock anymore so I had to zip tie it.

My fuel basket had a arrow to align on top, dont remember it may be under the lock ring