Fuel tank level Gauge

[Gamble]

I have not even began to locate my problem, but its pouring the rain so I thought I would get ideas from you guys in the meantime. I was working on my jeep down at a friends house last night, had about 3/8 tank of fuel and after sitting on a steep hill for a few minutes, both running and not. When I returned to my truck it was showing low fuel light and gauge was down past empty. I of course checked to make sure I had not had a leak or fuel line come off and I did indeed still have fuel. I thought it might have been just because of sitting on the hill, but the gauge remained below empty and light on for the entire 35 mile ride home, and I stopped to put about 10 more gallon of fuel in it just to ease my mind. I am hoping the sending unit came unplugged while I was dragging my trailer out of the field but like I said, its raining and I don't have a place to stay dry at the moment, Truck wont fit in the garage. lol. Any other ideas from you guys would be appreciated. No codes, no CEL. Just stopped. Thanks.

[Homestead]

It's probably safe to say that the sender in the tank is dead.My 02 has had 3 over the years so I'm thinking if you are a 99, it's time.The thing that kills the sender the most is high speed filling at pumps such as fleet card lock or where big trucks fill. The volume compared to a regular gas station beats on the float assembly pretty good and it's only a matter of time.I fill at a card lock and that's what I'm sure killed mine. They are fairly simple to replace. Drop the tank a bit and slightly rotate it, change the sender and be done with it. About and hour or so in time.Jeff

[Gamble]

Thanks,I figured that was probably going to be the case, but sometimes there are simple fixes that are often overlooked. I am still going to do a diagnosis before hand. I mostly just dread the thought of dropping the tank and changing it. Last time it had way to much fuel in it. LOL. Will have to siphon it out before hand this time. On a side note: Can you buy just the sending unit for these trucks, or is it a pump/sending unit assembly?Thanks again.

[Homestead]

I can't remember the price off the top of my head but it was reasonable enough I just bought 2 of them. The extra one has been sitting on the shelf for about 2 years now.It is just the sending/float unit itself. When they hand you the box, you will swear there is nothing in it.Jeff

[MnTom]

A lot of times you can repair the sender. The easiest way I have found is to lift the box and pull the fuel module. Once you get the sender out then you can look at it and see where the problem is. Most of the time you can 'adjust' things and it will work just fine. On mine I was able to flip the wiper over and it has worked for over 8 years!

[Gamble]

I had considered just lifting the box this time, Seems like it would be easier anyway. 4 bolts and a tank neck are much easier than all that work under the truck.

[MnTom]

I had considered just lifting the box this time, Seems like it would be easier anyway. 4 bolts and a tank neck are much easier than all that work under the truck.

Yep. Leave the two rear bolts loose without removing them then it will act as a hinge. Just be sure to block the box up while working under there! Oh, BTW, the bolt size for the box bolts is 15mm.

[Aggie08]

Where can you order the new float? Dealership or does the local auto store carry them? Thanks

[Mopar1973Man]

Dealership only item and here is the information on it.

http://articles.mopar1973man.com/2nd-generation-24v-dodge-cummins/25-fuel-system/236-fuel-gauge-replacement-sender

[SNKEBIT]

Definately easier to lift box. Have done 3 box lifts this month. I WILL NOT lay under another truck again!As for the sender, most of the time the cheap plastic piece that the arm mounts to is worn out with slop and can't hold the arm straight any more so the contacts for the sender aren't touching all the time. I just make a cheap bushing and reinstall the arm and good to go. Works on all the Mopar tank senders.(Had to learn this because in the past, could only get the sender with the fuel pump module.):banghead:

[Aggie08]

What type of bushing is being used? And to be clear you did not have to buy a new one, just refurbish the old one? Thanks

[SNKEBIT]

Sorry, last post I got mixed up. Bushing was a different fix. lol Just fix old sender.Take a soldering iron and melt the edges of the hole for the swing arm just a little to fill in some of the hole. You can do both sides of the plastic piece. Then get a drill bit the same size as the swing arm and drill hole out the hole. Press arm back in and check to see if swing arm can move freely without side to side slop.I have fixed half-dozen or so this way.