Fuel Guage instability - Dodge Cravan '96 3.0L

In my Dodge Caravan '96 (3.0L engine) the fuel gauge jumps all over
the place and triggers the sound of low fuel level, when vehicle is in
motion, especially when I break. It happens more frequently when fuel
tank is full or close to this level. Sometimes the problems goes away
for weeks at a time only to come back later.

What is causing it, and where exactly should I look to fix this
problem, I do not see any loose wire connection or damage to a wire
harness under the hood.

Any help would be greatly appreciated.

Matt

 

Go get the recall done for the in tank fuel pump module. If the gauge still
jumps all over the place, go back and complain to the dealer about it. They
had to replace the module, and the tank because they screwed up the recall.
Also, get the fan relay recall done too. The dealer destroyed and had to
replace the PCM in the process of doing that recall.

 

'Go get the recall done for the in tank fuel pump module. If the gauge still
'jumps all over the place, go back and complain to the dealer about it. They
'had to replace the module, and the tank because they screwed up the recall.
'Also, get the fan relay recall done too. The dealer destroyed and had to
'replace the PCM in the process of doing that recall.
''> In my Dodge Caravan '96 (3.0L engine) the fuel gauge jumps all over
'> the place and triggers the sound of low fuel level, when vehicle is in
'> motion, especially when I break. It happens more frequently when fuel
'> tank is full or close to this level. Sometimes the problems goes away
'> for weeks at a time only to come back later.
'>
'> What is causing it, and where exactly should I look to fix this
'> problem, I do not see any loose wire connection or damage to a wire
'> harness under the hood.
'>
'> Any help would be greatly appreciated.
'>
'> Matt
'

Thanks for the reply Bob.

The fan relay recall was done a few years ago but that was the last
recall notice that I ever received. My address is unchanged and I
never received a notice on this in tank 'fuel pump module' recall. I
would greatly appreciate if you could indicate the recall number and
any other info that is available to you.

Thanks, again

Matt
'

 

Admin Net*

Yes, Bob - if you could please post the recall number, or how to locate it I,
too, would appreciate it.

Thanks!

R. Phillips

 

There's several for that vehicle. I had one. Look here for details:
http://www-odi.nhtsa.dot.gov/cars/problems/recalls/ Also, you need to
complain about the airbag light coming on intermittantly. They need to
replace the clockspring, but they won't do it until it fails - SRS light =
open circuit to airbag squib = airbag inoperable. I tried to get them to fix
it prior to the recall. I got to pay for the clockspring, and no, I cannot
get a refund because I don't own the vehicle anymore.
Recall number for fuel tank:
99V216000

 

This problem sounds like a bad sending unit. Is that part of the fuel pump
module? I wasn't aware there was a recall on the fuel pump module. I had
my sending unit replace a few years ago for this exact problem and paid for
it.

 

There isn't one on the module, it's on the gasket and nut. Quite often they
wind up having to replace the module, and the tank because things don't go
back together right, and it leaks. It happened to mine, and both of the
Caravans my parents owned. The idea here is that if they have to mess with
it anyway, let them, and if they break it, or find it broken, it'll be be
fixed. If the gauge still wanders after they're done, ask why the gauge
keeps wandering.

 

David:

Do you recall what the cost of sending unit replacement was?

Do you know where is the sending unit located, is it an easy DIY?

Thanks

Matt

===========================================================
'This problem sounds like a bad sending unit. Is that part of the fuel pump
'module? I wasn't aware there was a recall on the fuel pump module. I had
'my sending unit replace a few years ago for this exact problem and paid for
'it.
'
===========================================================
'> > In my Dodge Caravan '96 (3.0L engine) the fuel gauge jumps all over
'> > the place and triggers the sound of low fuel level, when vehicle is in
'> > motion, especially when I break. It happens more frequently when fuel
'> > tank is full or close to this level. Sometimes the problems goes away
'> > for weeks at a time only to come back later.
'> >
'> > What is causing it, and where exactly should I look to fix this
'> > problem, I do not see any loose wire connection or damage to a wire
'> > harness under the hood.
'> >
'> > Any help would be greatly appreciated.
'> >
'> > Matt

 

I had it done a few years ago and can't remember how much I paid. Probably
around $300 parts/labor. I've done this job on my '88 and am familiar with
that, but not the '96. I imagine you have to drop the fuel tank to get
access to the sending unit. Dropping the fuel tank has some complications
the first timer will need to prepare for, such as preventing the vent hose
from breaking, spilling fuel, disconnecting the filler tube and supporting
the tank while it's unbolted. The other thing is cleaning the top of the
tank to prevent dust from falling in (and fouling the fuel pump).

 

Hi Matt,

Had the same problem about a year after I purchassed my 96 Dodge Caravan...

Problem was in the sensor located inside the gas tank with the pump
assembly.....

Had to get it replaced....only thing mine at the time was under
waranty....good luck

Latter...