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Discussion Starter · #1 ·
On our recent trip to Oregon, the fuel gauge would bounce all over the dial. This only happened when the rear tank got down to a quarter. If going around a corner or going up or down a hill, the needle would be maxed past full then bounce down and up and all over. Didn't do this on the other tank when it was down to a quarter tank. I assume it must be the sending unit. Has anyone seen this issue and have a resolution?
 

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I would agree that you isolated the problem to the rear tank sending unit. I have not had this problem, but looks like the only way is to find out is to drop the rear tank, and pull the sending unit.

Hopefully someone will read this who has had this same problem and help out.
 

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Click this & read the captions in the photo album:

 

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Discussion Starter · #4 ·
Steve83

Thanks for the link. Good stuff!
 

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Discussion Starter · #5 ·
Well, here is an update. Decided to fill up both tanks and see what happens. The rear tank now sits at 3/4 full when full and the front tank is completely pegged past full. First time I've seen them act like this. I doubt it would be both sending units. How about a connection on either the tank switch or a connection on the instrument cluster? Guess I need to pull the cluster and at least check it out. While it is out, I would like to change all of the bulbs on the cluster. Has anyone switched to LED lamps for the dash? Any thoughts on the gauge issue?
 

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I doubt it would be both sending units.
I don't - they're the same age, and have been exposed to the same conditions. IME, it would be doubtful to find a truck with only 1 malfunctioning fuel level sender.
 

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Discussion Starter · #7 ·
Any ways to repair a flaky sender? Finding they are not inexpensive to buy. Any way to check them once they are out? Anyone know the resistance range a working sender unit should have? I know some are low resistance when full and high when empty and some are opposite. Any chance it could have anything to do with the tank switch?
 

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Ford says 16~18 Ohms empty; 146~160 Ohms full for all truck fuel gauges ~'87~04.
 
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