fuel tank sending unit on 02 dodge

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quad - 28 Oct 2007 23:56 GMT

I have a 02 dodge 3/4 cummins and the fuel gage reads 1/4 tank and the
tank is empty. I bought a new sending unit and lifted the bed of the
truck and removed the in tank metering assembly. in looking at the
metering lever it looks like the float my have been hanging up. I am
trying to replace the sending unit and I can't figure out #1 how to
disconnect the sending unit wires from in tank metering assemble Plug
and #2 how to release the sending unit from the assembly. thank you
for any help.

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BigIronRam - 29 Oct 2007 16:00 GMT

>I have a 02 dodge 3/4 cummins and the fuel gage reads 1/4 tank and the
> tank is empty. I bought a new sending unit and lifted the bed of the
[quoted text clipped - 4 lines]
> and #2 how to release the sending unit from the assembly. thank you
> for any help.

I have the same problem with my '01, I'd be interested in what you find
out.

Mine started out actually being empty when the gauge hit empty, (no reserve
at all) now it's up to 1/4 tank reading is empty like yours.

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Nosey - 29 Oct 2007 16:27 GMT

> I have a 02 dodge 3/4 cummins and the fuel gage reads 1/4 tank and the
> tank is empty. I bought a new sending unit and lifted the bed of the
[quoted text clipped - 4 lines]
> and #2 how to release the sending unit from the assembly. thank you
> for any help.

I replaced the fuel sending unit in my '99 diesel. I ran out of fuel with
just over 1/8 of a tank.
I think my module might be different than yours. The parts guy had a hard
time finding the right sending unit for my truck. Does your fuel module look
like this?
http://i24.tinypic.com/15xqrsi.jpg

To remove the wires I had to grind a small screwdriver down to release the
locking tab inside the connector. That was a huge pain in the a.s. If I had
to do it again I'd cut the wires and splice connectors on the module side
wiring that mate with the factory connectors on the new sending unit. On my
module the sending unit slides down the track and off the bottom. I don't
remember how it was released from it's position but I don't think I had any
difficulty with it.

Signature

Ken

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quad - 29 Oct 2007 18:19 GMT

> > I have a 02 dodge 3/4 cummins and the fuel gage reads 1/4 tank and the
> > tank is empty. I bought a new sending unit and lifted the bed of the
[quoted text clipped - 20 lines]
> --
> Ken

Ken, Yes this is the same assembly. I was wondering if the plug the
wire ends were in could be removed and make getting the new ends easy
to R/R. If I splice the wires it may change the resistance and the
gage could read incorrectly?
Bob

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Nosey - 29 Oct 2007 19:37 GMT

>>> I have a 02 dodge 3/4 cummins and the fuel gage reads 1/4 tank and
>>> the tank is empty. I bought a new sending unit and lifted the bed
[quoted text clipped - 26 lines]
> gage could read incorrectly?
> Bob

Splicing the wires might throw the gauge off. The PCM reads a voltage signal
from the sending unit instead of resistance but I suppose the end result
could be the same with a poor splice.
The 2001 FSM mentions removing a locking collar from the electrical
connector before the wires can be released. I don't recall removing any
collar from the connector on my '99. Maybe that's why it was so difficult.

Signature

Ken

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