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Car Forum / Dodge / Dodge Trucks / May 2005

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97 Ram 3500 w/Cummins and 5 speed manual.

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Hobart Duncan - 21 May 2005 19:16 GMT
My first diesel !!! and I love it.

Thanks to those in the group for enlightening me on the what's and what-ever's
and helping me look for the right vehicle.

Of course it came with a few flaws....(cruise not working - broken vac. line,
LH & RH electric mirrors WAY too sloppy, crack in windshield washer reservoir,
etc. but, those are taken care of now.  It's time to take on the bigger chores.
It seems this truck has been struck by the infamous "fuel level sensor"
problem.  I took a look under the truck this morning and I can see a problem
dropping the tank.  There seems to be tighter than normal spaces to allow the
tank to drop without any problems.  I have read in other areas that most people
raise the bed to access the tank.  As I look at the problem now, it seems if I
remove the 4 bolts to the front and just leave the 2 rear bolts loose, I should
be able to put my hydraulic jack toward the front of the bed and lift it until
I can get enough space to place some timber between the bed and frame rails to
support the bed while I work on the tank.

How much space between the bed and the tank will I need to remove the
component(s) ?  Is there a repair for the "sunk 'in/saturated float" or will I
have to opt for a complete new sensor.  I've been told that the plastic parts
either wear or become out of alignment as to work properly.  One person had a
great idea in replacing the existing pivot pin with either a piece of aluminum
or brass (welding) rod.

I was going to tackle the job starting this morning but decided to wait until
Monday when most Dodge/Mopar shops will be open.  I hate it when I have to wait
for a dealership to open.... and I don't know if the local AutoZones, Krager,
etc. will carry such parts.

I guess what I'm asking for is someone with experience (having done this
before) for advice.  If I have to rig a toilet float.... I'll do that too....
WAIT A MINUTE.... I was trying to be funny, but that may be a solution....

The project starts Monday morning.... any help before then would be
appreciated...

G. Hedlund
Zip: 92404
Researching: Hedlund, Anderson, Nyrén, Jansson,
Heggi, Laszlo, Tako, Taney, Luchinger, Toensing,
and Haufle.
Roy - 21 May 2005 20:04 GMT
> My first diesel !!! and I love it.
>
[quoted text clipped - 51 lines]
> The project starts Monday morning.... any help before then would be
> appreciated...

I've read about lifting the bed but I dropped the tank. Which ever way you
do it you might want to pick up the large "O" ring at the dealer along with
the module. Also some fuel line to replace the line from the tank to the
hard line at the frame. It always seems to leak a week after you have
finished the job.

Roy
Hobart Duncan - 22 May 2005 16:25 GMT
>--I've read about lifting the bed but I dropped the tank. Which ever way you
>--do it you might want to pick up the large "O" ring at the dealer along with
[quoted text clipped - 3 lines]
>--
>--Roy

Tnx Roy,
I've already planned on replacing any lines that connect to the hard lines.
When you say "the module", are you talking about the WHOLE assembly?  Maybe
I've been reading too many X-posts about the subject and confused myself....
isn't there two parts to the assembly and the only part that would need a
complete replacement is the float and rheostat module?  I understand it
connects to the main assembly with three machine style screws (into plastic).

From the pic in the Haynes repair manual, the units look identical with the
exception of the fuel pump for the gassers.  The sending units appear to be
replaceable in both cases.... am I correct?

Dropping the tank (according to Haynes), I have to remove the inner wheel on
this dually.... It seems more work than lifting the bed....  I'll be on my back
again today (before the temps are over 95) and recheck everything.  I've
removed the "GooseNeck" hitch that came with the truck.... I'll be fitting a
5th wheel hitch on the rails that the GooseNeck was bolted to.  I'm also
flirting with the idea of cutting an inspection plate in the bed to access the
fuel sensor module.  Then when everything is fitting... I'll have the bed
sprayed with a liner.

Have you or anyone else played with the idea of cutting out a section of the
bed over the tank just large enough to yank that module out in the event it
happens again?  I'll tell ya, I'm giving it some deep thought right now.

again, Tnx....
Gerry of San Bernardino, CA.
 
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