I'm at a loss

motoking_1990

motoking_1990

Active member
May 9, 2011
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Terre Haute, IN
So I did the fuel lvl sender swap posted by Rebel on the dp forum. Used the 6.0 sender with my float. I'm getting resistance on top of the tank now. (It didn't show anything before) Still have no fuel gauge. A couple weeks back I took the voltage gauge stepper and put it in the fuel level gauge to see if it would fix it......it didnt. So I put a new sender in.

When I move the float arm to empty the low fuel light comes on the DIC and when I move above empty it goes out. So the sender is working now. Think the stepper is the issue? I'm about to just try and find a new cluster. Idk what to try next. :banghead:

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motoking_1990

motoking_1990

Active member
May 9, 2011
1,957
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38
Terre Haute, IN
When I first got the truck it would read fine til 1/4 tank then say empty. After a while it got worse and would be empty with low fuel ligjt then go to full of course it wasn't really full either, back and forth. Wasnt when I hit a bump it was just random. Now it's on e and the DIC says low fuel most the time every very great once in a while it will read full. These past few months I been trying to go it working again. It gradually got worse.

One guy had it on a scanner said it's reading right on his scanner so it had to be the stepper. Swapped it ... no change. Another guy hooked it up a couple weeks ago and said he scanner wasn't reading it at all so it must be in the tank.

Do I need to reset the needles again since I put the level sender in?

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NC-smokinlmm

NC-smokinlmm

<<<Future tuna killer
May 29, 2011
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At Da Beach
If the low fuel light is coming on when you set the sender at empty then it is working. The ecm gets a seperate signal to illuminate the low fuel light, I'd say the cluster is bad, I dont think the 02 uses stepper motors...
 
motoking_1990

motoking_1990

Active member
May 9, 2011
1,957
5
38
Terre Haute, IN
NC-smokinlmm said:
If the low fuel light is coming on when you set the sender at empty then it is working. The ecm gets a seperate signal to illuminate the low fuel light, I'd say the cluster is bad, I dont think the 02 uses stepper motors...
Click to expand...
They don't use those white ones like the 04.5 and up. The motors in mine are yellow look like a stator.

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496 BB

496 BB

Head Thread De-Railer
Feb 20, 2009
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At your girlfriends house
Heres what I would do to just make sure. Take out current sending unit and pump assembly. Buy another unit (DELPHI ONLY) and plug it in and see if it works. If its the same take it back and your not out any money. Just dont get gas on it. Do it outside of tank. Do existing outside tank as well for comparison. Even if both work outside doesnt mean old ones not hitting on inside or baffles inside. Personally I would have never scabbed another sending level on the existing pump body but thats just me.

If the new one works fine you know it was something in old setup. Now the other thing Id look at before ANY of this is the actual movement of the float itself IN the tank. ALmost acts as if its caught or cant move proper travel and that can all relate back to adding new part to it.

Of course check and double check your grounds for pump. Id redo it on bare metal frame.
 
motoking_1990

motoking_1990

Active member
May 9, 2011
1,957
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38
Terre Haute, IN
I'm pretty sure the sender grounds at the pcm. I will see if I can get my hands on a Delphi that's a dealer part iirc.

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