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Old 04-17-2011, 03:03 AM   #1 (permalink)
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Fuel Sending Unit Repair For Under $1

I found a way to fix your fuel sending unit for under $1. This works for the 94-98 dodge ram for sure, I don't know what else it works with. It is very easy to do. All you need is a drill and a spring from a hardware store. The spring costed me $0.69.

1) Drop your fuel tank and take out the sending unit.

2) Drill a little slot in your sender's support brace as shown in (Figure 1) below.

3) Insert spring into the pin of the fuel level sensor. Make sure you cut the spring so that there is the right amount of pressure applied by it when the bracket is mounted in the next step. (Figure 2)

4) Mount the brace UPSIDE DOWN so that it holds the spring in place. (Figure 3)


Figure 1


Figure 2


Figure 3
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Old 04-17-2011, 10:18 AM   #2 (permalink)
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Talking Great Post

Great info Man!
Wondering if this will work for my 01?
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Old 04-17-2011, 11:50 AM   #3 (permalink)
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Great info Man!
Wondering if this will work for my 01?
I'm not sure if your truck have the metal piece in figure one. If you have that then this fix should work.

BTW it works without the spring but we put the spring in there just in case the plastic worn out after 100k (like the original). Once the plastic is worn out a bit the spring will hold the unit down and hopefully we will not have to drop the tank again.
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Old 04-17-2011, 01:08 PM   #4 (permalink)
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Yep, I tested it without the spring and it works, but it will be good insurance .
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Old 04-17-2011, 01:09 PM   #5 (permalink)
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So the reason causing it not to work is the plastic wears out and lefts the level shift enough that the sensor cannot tell theres fuel?
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Old 04-17-2011, 01:18 PM   #6 (permalink)
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Yea, the plastic wears out nearly 1mm and that's too big of a gap for the sensor detect any resistant from the board. Once you have it out you can test it with a voltmeter and make sure everything is working before putting it back
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Old 04-17-2011, 01:21 PM   #7 (permalink)
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Correct, there is a plastic "washer" that wears out over time. You can see it when you take out the unit. The plastic is there to keep the terminals in contact with the circuit board. By doing this repair, we are holding the sender's arm to the sending unit and therefore will have connection. I was looking at this:
CJ Johansson's fuel sender repair for reference.
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Old 04-17-2011, 02:54 PM   #8 (permalink)
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Ahh yeah i can see that happening. Well i got a full tank at the moment, but once i get that down ill give dropping the tank some attention and hopefully gettin this fixed. Thanks again!
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Old 04-20-2011, 08:49 PM   #9 (permalink)
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mine in my 01 stops working correctly (moves slowly) when it leaves the full mark. 1/2 tank reading is actually empty. so i'm gonna try this, but was wondering what spring you bought, and did you cut it down some from what your pic show, or did you just smash it all down in there? i've also had better luck taking the box off my truck, than trying to figure out how my fuel is in the tank.

also my third lift pump is going out, i know i should have put a good pump in! has anyone put the pureflow raptor 100 in? any problem with this pump? i'm planning on putting the edge juice in it this year, and was wondering if this pump is enough or should i go with the 150? Thanks!
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Last edited by HI HO Silver Away; 04-20-2011 at 09:00 PM.
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Old 04-20-2011, 09:30 PM   #10 (permalink)
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I bought one that fit from ace hardware. Bring the fuel sending unit to the store and find a spring that fits. I cut about 1/4 of that spring off from what the picture shows. Use common sense and just estimate how much force would be required to hold the arm to the sending unit.
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Old 04-20-2011, 09:45 PM   #11 (permalink)
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Thanks!, i'll do that.
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Old 04-21-2011, 12:13 AM   #12 (permalink)
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Whoa HI HO, you might have the sending unit in your truck that cannot be 'fixed'. There were a couple of different fuel modules in the 2nd gen's and they had different sending units. You'll have to pull the module to see which sender you have. The first pic is of the sender that can be fixed, The second photo is of the sender that can not be fixed. I think they were used from '99 to 2001. I had the "can't be fixed" sender so I had to buy a new one from the dealer for 65 dollars. Hope you are luckier than I was.

CAN BE FIXED:


CAN"T BE FIXED:
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