Replacing a fuel sending unit

[Goatguy]

Well, i recently got myself a 1980 dodge van. The old HUGE ones that fit more stuff in them than a pick up. Anyhow, the fuel gauge on it doest work and I'm thinking that it probably needs a new fuel sending unit. I am also assuming that I'll probalby need to drop the tank on it to replace it. Has anyone ever done this? Is it hard to do? Is it possible to do without a vehicle lift?

And finally, would an person with very little car repair expirience like myself be able to do it or would it be better to just take it to a shop?

Thanks for the help!

[danb98577]

Can be done at home-had a 1973 one ton-a beast. Drain the tank. Do all this outside if possible so fumes do not build up. DO NOT USE AN INCANDESCENT TROUBLE LIGHT. You will have to remove the obvious-filer neck, straps that hold the tank-soak well with penetrent before even attempting.
The retaining ring that holds the sending unit is a tap off-tap on style lock ring. Be extremely sure that the tank is drained and well ventilated before you start tapping on the ring. If you can find a piece of brass stock to tap with a hammer, the better. Sparks are not your friend here.
There is a rubber gasket under the assembly after you get the lock ring off-take care to not tear it and make sure it is in good shape. The rest is straightforward pull out/replace/assemble. Make sure the ground is good.
Above all, be safe. If there is any doubt, take it to a shop.

[Cabin Fever]

Here is an option you may want to consider.

My fuel gauge works lousy. Yhis is what I do. I reset the trip odometer every time I fill up. When I see that 300 miles has passed, I fill’r up again.

[tyusclan]

Originally Posted by Cabin Fever

Here is an option you may want to consider.

My fuel gauge works lousy. Yhis is what I do. I reset the trip odometer every time I fill up. When I see that 300 miles has passed, I fill’r up again.

My daughter does this on her Jeep Liberty also. Only, her tank's not large enough to go 300 miles.

[watcher]

My old S10 doesn't have a trip meter. I keep a dry erase marker in it and right the mileage on the rearview mirror. When I fill I write the mileage on the mirror.

[fordy]

...............Were you to take that van too a repair shop they would put it on a lift , disconnect those straps that are attached to the frame and then lower it down by hand . They would have also removed as much fuel from the tank as possible .
..............Too drain the tank , buy a 12 volt dc fuel pump as cheap as you can find , then purchase about 20 feet of 5/16th's fuel hose . Now , take the fuel hose and start shoving it into the tank via the fillup spout , should take about 5 to 7 feet or so , then set the fuel pump ON THE GROUND , so it is lower than the bottom of the fuel tank . Turn on the fuel pump , and attach the loose end of the hose too the SUction side of the pump and it should start pumping out the old gas . Now , at this point you can remove the fuel pump , and cut the hose and then reattach to the suction end of the pump as before , while it is(still) laying on the ground . NOW , attach the remaining length of hose to the pressure(outlet) side and pump the gas into 5 gallon gasoline containers until the pump has removed .....most of the fuel .
...............To provide power for the pump , purchase one of those plungin deals for the cigarette lighter and enough 14 gauge wire to reach the pump as it is laying on the ground : I would say about 30 feet or so as you will have to have (2) wires , one for the positive and one for the negative . The positive terminal on the plugin thingy is the Center piece . Note * most fuel pumps are good at pumping , but very weak on the suction side so this another reason for laying the pump on the ground , below the bottom of the fuel tank . Good luck , fordy

[tamsam]

OK first thing I would do is try grounding the tank. I had to do this once as it had lost its groung due to rust. Sam

[Beeman]

The first thing to do is diagnose the problem. The fuel sending unit in the tank is a rheostat that puts resistance to ground. If your fuel gauge goes past full when you turn the key on it indicates an open in the circuit which could be a bad gauge or disconnected/broken wire. if the gauge stays on empty the circuit is grounded indicating a bad gauge or the circuit shorted to ground. Of course a bad sending unit can cause these conditions also. Disconnect the sending unit and turn the key on, the gauge should go past full. Then ground the wire and the gauge should go to empty. if this work OK then it is either the sending unit or it's ground circuit.

[Goatguy]

hhmm.. Interesting! I'll give it a try, Thanks for the suggestions folks.