Cummins Fuel Level Sending Unit Fix

[@raychilcote5558]

Great explanation. Appreciate your efforts. I'm big on telling folks that parts are wearable (vehicle... and most everything mechanical). They have a lifespan and at some point, a part wears out. Fuel pumps, alternators, pulleys, water pumps... essentially, anything that has movement. You showing the contacts on the sending unit and telling folks why that causes issue... that's golden!

[@SuperPetrolhead87]

The start & ending on these videos are top notch!Ive never removed a fuel tank and not found crud..... or metal fillings on the diesel vans over here.keep it up mann

[@briansmobile1]

Thanks! I got new software. I keep trying to better the channel a little at a time as I can afford it.

[@hectorglover6392]

awsome! I have a 2001 Dodge 3500 with the cummins and i had the same issue when it was just out of warranty. In about a month it went away by it self. Perhaps one of those plastic items swimming around got it stuck! But its a 300K and still going. I too love my truck. thanks for the video and Merry Christmas to you!

[@IBMSystemsEngineer]

Liking the 1080 definition, even the 480/720p looks great. Nicely done. thx.

[@plokiu]

Thanks for the video, you struck a nerve with not being able to sleep comment, glad to hear someone else also has this problem with mechanical things. Except I'm bald !

[@BigIronTV]

Nice video. Just the solution I needed to address my half tank problem that just started. I have the same issues when stuff is not working. But that is a characteristic that makes a good mechanic. At least that is what I tell myself.

[@chilidog73]

I have a 2001 that is on its 3rd Injection Pump. It's a reman about 9 yrs old abd it has an OE carter pump that was replaced at the same time. Suggestions for avoiding future issues. The carter pump was reading psi around 12 psi before the fuel filter. But I have a sensor light that was installed by the previous owner to monitor the pump pressure. Supposed to some on if psi gets to 5. But it flashes sometimes, doesn't other times. Sometimes when I'm climbing a hill it will flash heavily, when I let off it goes off. Any help would be appreciated.

[@whatsit2ya247]

I assume either you don't own the truck anymore or trashed the crappy Carter lift pump for something you can actually get and adjust pressure.

[@chilidog73]

@@whatsit2ya247 I finally replaced it with an AirDog 150. Just before that I added a Glowshift sensor and I was getting around 5 psi down to 0 at WOT. So I had to do something. Those stock pumps are just crap. Mechanic said it was working fine but it didn't seem right to me and I didn't want to lose another IP.

[@whatsit2ya247]

@@chilidog73 yeah been there done that pretty much exact same thing. Running 17psi

[@dlynster]

Hey Brian, thanks for the video!! Any pointers / tips in reinstalling the unit? It seems like mine won't go in / all the way down (gasket is catching but beyond that, even when I get the rubber gasket to not crimp/crinkle) due to the sender float bottoming out in the tank.

[@hawkie333]

Gotta get rid of that lift pump if it’s oem. The VP44 will fail from lack of pressure, and it is way too far forward....the FASS and AirDog are both good options, esp now that they are brushless.

[@nathancarter8405]

Thanks, this helps me. Are you in Utah?

[@ecklisalisa8630]

question for you: I have a 1996 12valve cummins,( mechanical cam driven lift pump). I had a breakdown with 1/2 tank of fuel on- went over a bump dash fuel gauge went haywire and then to E where it has remained (no massive leaks etc.)and then truck stalled out starved for fuel. I put new filter on in case it was a clog/contamination, bled , restarted. It is running OK but if I push down hard on the pedal while driving it acts normal to about 1/2 way down and then it's like it doesn't change or increase the fuel volume, so, from 1/2 way to floor it just doesn't do a thing. I suspect my fuel tank module is messed up and not picking up fuel properly. Mechanical lift pump seems OK. Idles fine--just when you "get on it" it's like it only will supply X max amount. Since this breakdown it starts right up but runs a bit rough blows some white for a few minutes (like you might experience in cold/winter temps but it's warm/summer) My garage suggests changing the OFV, which I think sure mights well---but my hunch is the tank unit is messed up. Any opinion you have on this welcome, also if you think tilting the bed (8ft) is an OK method for this BTW I have checked fuel lines and connections for leaks, they are OK.

[@waynec6059]

I'm the same way, shiznat keeps me up at night if I don't figure it out. Actually diagnosing a P0300 on a friend's 2002 xterra today while it snowed again. Finally got it sussed out with a backpressure test, passenger cat it would seem, has crumbled and blocked that side. 6+ PSI on that side..yikes.

[@briansmobile1]

Good job!

[@ishingwithjake2830]

I have 02 Cummins fuel gauge works to half way. I watched this video then called my local dealership and said could not sell just that part so wondering if different year would work or why they wouldn’t sell only as whole modular for $419

[@superduperrobb]

the graphite wore through the contacts. and because of they way it's assembled you can't move the pivot point so the graphite touched a different part of the arc. sucks that the replacement was $75 for what could have been avoided by lighter spring pressure on the graphite contactor.

[@2eagle86]

Ive got an 89 Ford F250 and my gas gauge doesnt seem to work good as well, everytime i fill up it only reads 3/4 and fluctuates to 1/4 when the gas goes low. Could that be my sending unit or something with the ground? cause if it is a ground issue i cant seem to find it "ground wire" what do you think??

[@tylerphelps4868]

Seeing the trouble code on your truck reminded me about mine. On 94-01 ram 1500s and 94-02 2500+ trucks, cycling the key from off to on 3 times in less than 5sec will tell you the code. 94 til I think 95-96ish will flash the numbers thru the check engine light, OBDII (96ish-02) will read it on the odometer, if you see this could you share with viewers?

[@briansmobile1]

Sure! Love too. This truck will do that too, but to clear it you have to disconnect the battery or use a scanner. Great topic. Will throw in Chevy, Toyota and Ford methods too.

[@Halffast719]

I'm thinking about getting a edge juice with attitude CTS for my Optimus Dodge. How do you like it and would you buy one again? Maybe do a quick review on it.

[@briansmobile1]

I love it. Yes, I would buy one again, but sooner.

[@Leckrovov]

thanks helps a lot ive got the same problem on my 94 12v now i know its not gonna be too hard to do.

[@briansmobile1]

Welcome- good luck!

[@nd318865]

Well done. Do you use fuel conditioner regularly during the winter months? Curious.

[@mikesenn1691]

Does anyone know how to take the cap where the sending unit wires run into out so you can access them for the new wires to plug into?

[@SushiPac]

Sweet happy you got that all figured out. Thank you for sharing that with us :)

[@briansmobile1]

Welcome Paul!

[@Konadawg99]

Awesome video man. Thanks for posting! Also, this makes me want to get and edge tuner for my cummins. I had no idea that you could clear out a trouble code that easy. You rock sir! questions: 1 do you use a dummy light or a gage for the fuel line pressure? Is that also available on the edge tuner? 2 I have an 03 5.9 l cummins. is that model prone to lift pump failure like the 2nd gen diesels are? 3. have you gained any MPG's by using the edge tuner?

[@desertfox2020]

I'm shopping for a 2nd gen Ram, and I was wondering, if I'm not going to do any towing, is it justifiable to get a Cummins model over one of the gassers? I know the fuel economy will be better, but do the extra costs outweigh that?

[@muncleike]

Hmm my ram gets like 12mpg, 5.2L gas, not sure what the price difference is but if you do alot of stop and go driving it will suck the gas down fast! Any fuel economy improvement would be smart. Jmho

[@desertfox2020]

muncleike Thats terrible. I had a 5.2L gas and it got a steady 14-18 combined. I also had a V10 and it got 11 combined. Diesel costs about .50c more a gallon here, and maintenance costs for a diesel are also higher.

[@briansmobile1]

desertfox2020 My advice is get a diesel if you tow something 10K lbs. or more. Otherwise--- enjoy low maintenance, better ride quality, easy fueling, easy starting, and less expensive fuel.

[@desertfox2020]

briansmobile1 My 5.2L Ram ran up to 200k with few issues. It ran up to 265k with a fair share of problems and then oxidization claimed the frame. Thanks for the advice. Do the diesel trucks ride even worse than the 3/4 ton gassers? I had a 2500 V10 and it rode so harshly that I only kept it a month, but I also thought it had worn out shocks.

[@Nordic_Mechanic]

keep diesel in mind if you do a lot of mileage. recently took the plunge for a diesel. My 3500 crewcab long bed dually does the same mileage as my v6 gasser 1500 ext cab short bed. I'm not going back. Dont even need the small truck to save gas anymore. It's like the big truck became the economical go getter.

[@louchavez1069]

p0463 what do I need do first because my 01 running down road and seem like I lost power and comes back on so there's code p0463?

[@Dj-us8jh]

What’s the part number?

[@danielmarshall5695]

how to fix the number 3 fuse under Hood keeps blowing soon as you put it in

[@stonent]

Looks identical to the one on a 2002 galant. Even the pump looks the same. Strange considering the engine is 2.5 times the size in your truck.

[@MusherDeeds]

brian, ever think about getting an upgraded lift pump like an airdog or a fass? or do you already have one? I have the same truck and was thinking about going that route to as to not tear up my injector pump. Great video!

[@briansmobile1]

I have the FASS. It came with the truck. The previous owner had it in and out of the best diesel shop in the state. New EVERYTHING and it still had no-start issues. I bought it cheap! And all set up. The problem was a $30 rebuild bleeder kit.

[@MusherDeeds]

briansmobile1 If you have any interest in installing a 3 cylinder high idle switch on your truck, I drew up the wiring diagram. All you need is a few plugs, switches, and resistors. I'm hoping to make a video soon as I am installing it on my truck for those cold mornings. Diagram: plus.google.com/u/0/b/117109788071295198864/117109788071295198864/posts

[@briansmobile1]

Love to see it!

[@MusherDeeds]

briansmobile1 It a simple fooler for the IAT Sensor.. all the parts and things you need are listed. plus.google.com/u/0/b/117109788071295198864/117109788071295198864/posts

[@willmo454]

I just put a sending unit in from dealer. Still reads empty on gauge. Computer DTE reads “SC”. Any ideas?

[@Dive-Bar-Casanova]

Hondas are notorious for bad fuel sending units. Especially the S2000. Would love to see how to fix them.

[@TheTx2styp]

Howdy Brian...what is the diagnostic reader you are using to reset codes?

[@briansmobile1]

It's main function is tuning and gauges. It happens to read and reset codes as a bonus feature.

[@briansmobile1]

briansmobile1 I'm sorry. I didn't answer your question. It is an Edge Juice with Attitude by name.

[@TheTx2styp]

briansmobile1 Thx...I have 98 12 valve with column 2 gauge ....boost and exhaust temp. Custom dual turbos larger injectors and strings. So, I don't think I would benefit much with the Edge.

[@knunne1]

Thanks for the video! Great intro graphics too.

[@4g63tpowered]

Those sending unit floats seem to be quite a bitch to get ahold of now. Everything on back order. I'm convinced this is why my fuel needle jumps all over with a quarter tank of inaccuracy and will also not go below a quarter tank. Good clarifying vid. What I also expect to find. Truck has 488k things bound to be wore out

[@Crazystuffyousee]

Good video. Thanks for the heads up on the sender.

[@imtheplayerandthecoach2409]

I have 2001 24v has fass an sump I never had problems I change fuel filters regularly had truck four years now anyways other day I was driving an sorta low on fuel next day have too codes p0460 p1693 an she was sluggish low on power checked turbo an for boost leaks is this my corporate did you have same code or problems have poor fuel mileage an low boost low on power

[@phishter]

Thanks Brian for the great Ram vids. Who makes that front winch bumper you have on there?

[@briansmobile1]

A local guy with a red beard made it.

[@desertfox2020]

He has a series of videos in which he makes it

[@phishter]

briansmobile1 I should have known ;)

[@muncleike]

Mines doing this with a brand new pump, well it was brand new and has been doing it from day one, thats what I get for not checking the gauge before I put the bed back on :(

[@briansmobile1]

That should be an easy fix- maybe it's just not connected completely at the top? Those red tabs sometimes block a complete connection.

[@muncleike]

Hey thanks brian I will check it out...in spring! Lol I hope thats it the only reason I didnt go back into it I because them damn clips and plastic hoses like to break. Buy the way got any advice, my window froze to my rubber seal ( I know I should have done the wd40 trick ya just showed us) and when I tried to roll it down it pulled out of the frame slot thingie in the door. Is glue a bad idea? Its hard to get between them little holes in the metal door lol

[@MBoone-ze3ch]

muncleike That has happened to me three times (2 different windows) on my '03 Ram. Pull the door panel off and put a little silicone in the metal groove that holds the bottom of the glass. Roll it up and leave it there for a day or two to let the silicon set up. Then use as normal. Has held my glass in place for 2 years.

[@muncleike]

Thanks was thinking of silicone, wasnt sure glue or silicone were good ideas if I ever had to replace the glass I dont think I could get it out, but ya got to do something!

[@fomoco300k]

muncleike Factory used double sided tape which wore out over time. I cleaned that up as best as I could, then I just put a few small dots of silicone because I was worried about how hard it might be to clean out if the glass ever had to be changed. Has worked well, so far. It just needs a little something to keep it from popping out of the track is all. Those Dodge door panels come off pretty easy... basically remove the latch handle and two phillips head screws at the bottom and lift. Then you can take a look in there and see how the window fits into the metal groove at the bottom of the regulator. Not to hard. I fixed my drivers window on my lunch break one day.

[@cleavisbutkus9373]

I undid the two bolts that hold the fuel tank but I can't figure out how to disconnect the fuel lines. I can't even see the fuel line's let alone disconnect them. nobody tells you this I guess it's a big secret

[@tommiller8416]

Good video lad, thanks!

[@AamirZ]

That must be a huge Diesel Engine you got there! Never seen it where the Rev counter only goes up to 4K. Most diesels the counter goes up to 6K, redline of about 5.5K or so. Well in UK everyone drives a small engines car other wise you get a big engine car and you'll be doing the government a favour in tax.

[@desertfox2020]

It's a 5.9L. That said there is a Ford 6.0 where the tach goes up to 6k so it's not necessarily dependent on size.

[@Nordic_Mechanic]

a truck diesel is 2.5k and 13+ liter. You dont need rpm on a diesel. A slow reving engine delivers more torque and wears slower.

[@moparman68]

Do yoi happen to know the part number for it?

[@Blockhead442]

Good greif! I'd be terrified to see the fuel bill, especially with diesel at $4.09 a gallon by Florida standards

[@ultraluffyyoutube3744]

It's almost at $300 XD

[@DavidAmmerlaan]

Right on.

[@briansmobile1]

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[@nathanbachorski8364]

Anyone have a part number? I can’t find it!

[@Cronus577]

www.genosgarage.com/product/04897669ab/fuel-tank-components

[@gunnarrkristinsson8437]

like your vidios had the same problom on my 1996 dodge

[@crx2di4]

part #???? have same issue. thx. complete lift pump module is 481...pass!!!

[@gassolean]

my fuel gauge was getting all fritzy too but it fixed itself :P

[@ratdude747]

You'd think the tank makers would vacuum out the tanks at the factory...

[@briansmobile1]

They're blown out with compressed air, but not everything comes out. You should see how much material was left in my little fishing kayak that's made the same way. They didn't even try!

[@ratdude747]

briansmobile1 Even worse are Aluminum Bicyle rims... Often times they'res all sorts of swarf and junk from drilling still inside. Usally good rim tape keeps that out of the tube at least...

[@MBoone-ze3ch]

briansmobile1 Brian, I am really hoping you cleaned that tank out and filtered the fuel. Makes me cringe to see all that debris in a fuel tank. I know, I'm a little OCD. By the way, why do you think Dodge doesn't put a serviceable filter on the Rams (gas ones at least)? I know... OCD again. Thanks for the videos!

[@1954BJohn]

who said 'There was NEVER any crud' in plastic fuel tanks Brian?

[@briansmobile1]

Someone said that only metal tanks have debris due to corrosion etc. They said modern tanks are plastic and are clean.- something like that.

[@gokartbuyer]

briansmobile1 well typically they are cleaner than metal ones. With the increased moisture in fuels due to the ethanol, the metal tanks get rusty on the inside.

[@DENicholsAutoBravado]

gokartbuyer Let me dispel an ethanol myth here. Ethanol actually effectively absorbs the moisture in your gas tank so it gets burned up in combustion. Water was more of a problem before Ethanol. Don't get me wrong, I don't like Ethanol, but at least it's doing one good thing so you shouldn't ever need the product Heat again, you know the product to help remove the water using alcohol? Alcohol and ethanol are very similar so they both take care of water problems.

[@DillysADV]

It's not that your a red head.. it bugs the cap out of me.. fortunate for you, you do have a warm garage to work in.

[@briansmobile1]

The warm garage didn't come cheap, but it's been worth EVERY penny!

[@asdeaff]

to sleep & dream of ................that bloody bike going up hill with no power again ! weird what`s it all about man

[@briansmobile1]

Bartle do..... house ply dried. Naturally. Sleep will come. Eventually.

[@briansmobile1]

briansmobile1 (now I'm trolling : P)

[@arthurdelapena2233]

O

[@hddm3]

ewww wwwwi geeewwwwwiiiii a!

[@briansmobile1]

I could not have said it better myself!

[@hddm3]

briansmobile1 hahahahaha love ya bri

[@joachimjohan1215]

dislike. this is not a fix this is parts swapping.