thrbrdrider

it looks like my sending unit is broken -- flat line on the gauge.

I did the diagnostic check and the cluster seems to be working: all gauges flipped around.

My mechanic says the sending unit and fuel pump are combined?? and they both have to be replaced?

however - the sending unit was replaced at 102,000 miles (2007) and the dealer's receipt says nothing about replacing a fuel pump. only a sending unit and fuel filter.

info please...

Thanks. Jeri

(sorry if this isn't drive train related -- I can move it)

Tallguy67

Thrbrd - some of our trucks (mine is one of them) have a lift pump in the tank. Others have a Carter lift pump on side of the engine block near the back of the block on the driver side and yet others have added aftermarket lift pumps. Take a look under your truck for an external lp between the VP44 injection pump and the tank. If you don't see one, get a helper to turn on the ignition and bump the starter but do not start the engine while you listen to the fuel tank. If the lp is inside the tank you will hear the buzzing of the pump inside the tank.
Once you know where you lp is, we can help you with the sending unit issue. I also wonder if there are some diagnostic you can do on the fuel level system to ensure you don't just have a broken wire somewhere. Hopefully one of the more experienced members will chime in to help with that.

SIXSLUG

You can replace the sender on the fuel tank unit, it is just that it is cheaper for a shop to replace the entire thing than fiddle with the fragile, brittle plastic that holds it all together...

Mine will sometimes act up, if I wiggle the electrical connector on top of the tank it comes back to life.

patdaly

Does the dealers receipt say fuel pump conversion kit? The reason I ask is this is Dodge's "fix" for the lift pump, take a second rate design and make it more difficult to fix, even though it is slightly more reliable.

If you post the Dodge part number for that item, we could figure out if they replaced a sender or did the conversion. You can also tell if on the drivers side of the block, under the fuel filter, see if there is a round cylindrical pump there or just a adapter block.

For reference, here is a illustration, look for item #1

http://www.wvodesigns.com/wiki/1998-..._%28VP44_IP%29

If you have that, your lift pump is as Cummins designed it, and your fuel module does not have a pump.

Just so you know, Dodge sells just the sender by itself, much cheaper than a rebuilt fuel module.

thrbrdrider

that's a good idea... my invoice from the dealer for the last sender says:


1900 Diag, replace sending unit, retest
9486 CP
1 4897669AB Levl Unit
Misc Fuel-5 Gallons
PO#107448
102226 2.5 tested and found that the fuel tank sending unit showed 1/8 tank of fuel but the truck was out of fuel. replaced the sending unit and retested.

B** Fuel filter Replace, Diesel
24C Fuel Filter replace, Diesel
9486 CPM
1 5015581AC Filtr Pkg
102226 .5 completed.


I don't see anything about a conversion unit

SIXSLUG

Doesn't look like it to me.

patdaly

Yep, that's just the sender, good, a dealership hasn't screwed up your truck yet!

Now, either you need to put in another one of that part number, or check to make really sure your wiring isn't the issue..........

deanwaltman

I don't know if this pertains or not, but I had a sender unit break the float clean in half, so the gauge read 'E' all the time. I found the halves floating around in the tank, cored a hole lengthwise in one of them, captured it with aluminum wire onto the 'L' shaped arm like it was before and it's worked for years. Even with half the buoyancy it still floats and reads. I used aluminum wire from my MIG. Of course in the process of getting the tank down, I broke off the quick connect (quick? not hardly) white plastic nipples off the top of the sender/filter unit. They suck. I MacGuyver'd it back together, but the best way is to NOT break them in the first place. If i'd known they were plastic I might have been more careful. A replacement was almost $500, could be different by now. My truck is a '00.

cougar

Which part number is the sending unit?

patdaly

4897669AB Level Unit this is the sender and float.

cougar

Awesome, thanks