1 1/4 tank fuel - Diesel Truck Forum - TheDieselGarage.com
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post #1 of 8 (permalink) Old 05-14-2011, 01:03 PM Thread Starter
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1 1/4 tank fuel

96 k2500 34gal diesel tank. Whenever i fillup the fuel guage shows i have 1/4 tank over full. I have not ran the tank near empty yet, but i was wondering why it would be off so much and how to fix it. Is it as simple as moving the needle on the guage or could it be something more complex such the sending unit? Any thoughts?

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post #2 of 8 (permalink) Old 05-15-2011, 12:30 AM
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Most gauges go more than just to the full marking. All of mine have at least. Best way to check to be sure would be to find the wiring schematic on the backside of the dash cluster or if you can see the contacts for the gas gauge (not sure as Ive never had that model year generation) take an ohms meter and read the ohms between 2 points at 1/2 tank and it should read around 45 ohm or so. These sending units are rated at 0 (being empty) to 90 ohms (being full) and relay that to the gauge. Could be as simple as a ground on the tank.

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post #3 of 8 (permalink) Old 05-15-2011, 02:46 PM Thread Starter
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I pulled the instrument cluster out but was not able to determine which contact goes to the fuel. The whole thing comes out and i cleaned the contacts from the dash to the cluster, its looks just like a computer ribbon cable, but the gauge is still roughly 1/4 off. Is there anyway to check the ground other than dropping the tank?

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post #4 of 8 (permalink) Old 05-15-2011, 04:22 PM
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A fuel gauge is a may or may not contain kind of thing it is not an exact reading.
What I would do is run it until the gauge gets to 1/2 then fill it and see if you put in 17 gallons.

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post #5 of 8 (permalink) Old 05-15-2011, 04:23 PM
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Hook up a temporary ground to the tank and see if it reads normal. If no change, that is what you have to live with. If it changes, add a permanent new ground wire.

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post #6 of 8 (permalink) Old 05-15-2011, 04:34 PM Thread Starter
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I can add 15-17 gallons when the gauge reads 3/4 full. When crawling under it i found the ground to the filler neck was snapped. Im gonna repair that one and try to put another to the tank itself. I can live with the gauge being 1/4 off all the time, but it just bugs me, i like having everything in working order ya know.

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post #7 of 8 (permalink) Old 05-16-2011, 12:27 AM
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There must be a specification for the sending unit when the tank is full. On a 96 gas unit the resistance when the tank is full is 88 ohms and when empty it is 2. I would imagine the diesel one should be the same. It is an easy check if when full it has higher resistance that would explain the gauge showing over full. Wife has a 93 Caprice and that gauge reads over full also.

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post #8 of 8 (permalink) Old 05-16-2011, 06:47 PM
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The one from the neck is for static when filling up. Go ahead and replace/repair it though. You may get luck and be able to feel up there on top of the tank for the ground but most likely not. There is a plug and a ground. You may be able to see the ground on the frame near the tank. Hard to tell where as when people replace them they tend to put them all over the place. If you add another one to the tank it has to go on the sending unit where it has a tab for it. Not sure on a diesel but it is a female wire spade connector on the ones Ive done. Another thing it could be is the gauge itself but would stick to the grounding for now. IF it bothers you that much and you DONT want to take off bed to inspect and clean everything I suppose you could move the gauge to where you want it by removing and resetting the needle. I wouldnt do it but its your choice.

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