Alright, here is something I have noticed.

Got my '02 in 06' I believe. Around '07 my lift pump and injection pump went bye bye. I had warranty still so to the dealer it went. First they shotgunned a lift pump at it(new style intank pump), sent me on my way, that evening dead pedal and then Monday they shotgunned a IP at it to cure the problem. After they did the intank pump and fuel prices started to sky rocket I noticed that my usual fill up at the pump went from 18-20 gallons to 24-26 gallons. I remember wondering why did my fill up cost change so much as far as gallons? I was filling up at the same point as before, 3/8 or so on the gauge. It had nothing to do with dollar amounts but with the gallons required to fill up and how much different it actually was.

Fast forward to now. About 2 months ago I bought a new old style tank unit from Dodge, the original design that came with the truck. I deep sixed the p.o.s they installed. As a business owner I am on top of my mileage. With the "replacement pump"(intank unit) I could go 300 miles on a half tank of fuel depending on how I drove but typically 300.

Now, with the "old school" no pump in tank unit(original) I have noticed that at 1/2 tank I am at 200-225 miles. Driving down the road and noticing that it caused a w.t.f moment. At fill up and a hand calc I discovered I am getting the same fuel mileage as before??? At 3/8 of a tank I am at 300 miles on the ticker. At this point I fill up the truck and oddly enough it only takes 18-20 gallons whereas before at 3/8 to 1/4 tank it was 26 or higher.

The thing that gets me is now I'm wondering if before, when I hit 1/4 tank if it was a "draw straw" problem or if I was really out of fuel because there is obviously something strange going on here.

Did Dodge just pull this "replacement" sending unit and pump out of a hat to stick in my truck? Has anybody else noticed this oddity?

 

Are you sure the sender was replaced when they put the in tank pump in? I didn't think it was necessary.

 

Yes, they replaced the sender and all, I have the original...original in the shop. Told them I wanted to keep it for future use and they were kind enough to cut the plastic hose for me. Still complete unit, sender and all...minus the plastic hose and connection on top of the unit that they wanted for their collection I suppose. Guess it was like collecting scalps? Who of all the mechanics replaced the most tank units with the even more worthless in tank "repair". Cut the hose and put it in your toolbox for proof!???

 

That is strange about the fuel level.

I do know I pulled down impressive mileage last summer with a 22 mpg run @ 65 mph from Kalispell to the coast. 600 miles and still had a 1/4 tank showing. Took just over 27 gallons to top off up the snout to the return hole.

Got home from same route/speed (65mph)New years eve on winter fuel and winter tires, heavier load, only got about 18 mpg, took 33 gallons to top up same. Gauge was showing E, but it was pretty cold so I didn't worry about the vp too much.