As the title says, the gauge said just over 1/4 tank, but when I went to start her, no go. (The tank was dry, I went 513 city miles on that tank and I drove her hard) The truck ran fine before I shut it off. Good thing I carry an extra 5 gallons of diesel. Had to crack injectors 1,3 & 4 (thanks for the info DTR members!!!) and after about 15 seconds she started, chugged, popped and farted a few times and away it went. (cool cloud of smoke though)

Ok, so how do I fix the issue, I filled it up and it says full now, but it seems the gauge sticks once it hits 1/2 to 1/4 tank of fuel.

 

The most likely suspect is the fuel sending unit in the tank module. Pretty common on these rigs. I keep track of my miles and try to never let it go below 1/2 tank. Mine would only go down to about 7/8 tank in about 300 miles. Replaced the sending unit and was good to go.

 

Yep, sending unit, less than 50 bucks at the dealer, ( just the sending unit, not the whole tank module )

 

So, to replace the sending unit I have to drop the tank?

 

You sure the gauge is sticking? I've heard of guy not installing the Draw Tubes correctly & sucking air. I see you have a Fass, just making sure.

 

I find it easier to tilt up the bed.
Remove four bolts on the driver's side loosen the four on the pass side.
Disconnect the fill and vent hoses.
Bed isn't that heavy, two people can tilt it up while another props it up.
Advantages to tilting are you don't need to run the tank down low, wiring and hoses are easier to disconnect and the tank straps, which have a tendency to break when spread open, aren't disturbed.

If you were to take it to the dealer where the job is piece rate they would tilt the bed.

 

My FASS is only the 95 gph and I did not put in draw tubes, just connected to the old connectors. Pretty sure it was dry, the tank holds 129 liters and I put in 131.

Tilt the bed, eh? Hmmm not sure if my garage is big enough, might have to do it with the door open. But that definitely makes more sense. Then I'll have more room to mount my Air-Zenith air compressor and tank. Then I can install my semi horns!!!!

 

When I went to install my Draw Straw, my stock suction tube was rusted & had a pin hole in it. The fuel tank is very simple to drop, just 2 straps & unbolt the filler tube from the bedside, it drops down. The bed has 8 bolts & gotta drop the spare to get the back ones.

 

His 2000 has plastic fittings instead of the metal ones like your 99.

However, he could be sucking air at the Dorman fitting. It's VERY common when using bypass pumps and no DrawStraw.

Dave

 

My 2000 ram did the exact same thing about a year ago. It read 1/4 tank and left my wife dead on the road. I added 5 gallons and got it running. Mine was definitely a fuel sensor issue, I'd guess your's is too.

 

I agree with this. It was just as easy to take off the bed and not worry about breaking anything.

 

I just got done with my truck. I had a constant "full" needle in the cab, but ran out of gas....with at least 10 gallons in it.
I pulled the fuel module, and all four screw points had broken at the top of the module. I had to modify it, and drill new holes. I put it back together, and now I can use all of the tank again.

 

This just happened to me - dead sending unit. Why do these parts suck so much? I used to like my truck - now I only like the engine. I hope Chrysler fails - they deserve it. Every single vehicle they make sucks.

I put in my drawstraw and airdog at the same time as replace the sending unit. I cracked the fuel housing, so got one from a junk yard. I hope this sending unit works, I haven't been able to put the truck back together yet as I am waiting on a different fitting since the airdog is not a bolt on install as advertised.