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Gas gauge on a 96 Dakota #3266042
10/23/24 02:09 PM
10/23/24 02:09 PM
Joined: Jan 2003
Posts: 10,920
Freeport IL USA
poorboy Offline OP
I Live Here
poorboy  Offline OP
I Live Here

Joined: Jan 2003
Posts: 10,920
Freeport IL USA
Yesterday I was driving my 49 Dodge truck that has the complete, unmodified 96 Dakota chassis, wiring, and fuel system in it. The donor truck only had 44,000 miles, but the odometer now shows 66,000 miles.

Consider this a 96 Dakota.

The pump and gauge sending unit was replaced when the truck was assembled in 2022. its been working great until yesterday. The gauge was reading just over 1/2 full while I was driving around. I stopped and shut the truck off for about 15 minutes, and after the restart (and several more since) the gauge now reads empty. By the mileage its been getting and the miles on this tank of gas, a 1/2 tank would be pretty close, the tank is definitely not empty. The other gauges are all reading OK, so its not a fuse. As best as I can tell, the wires on the tank sending unit feel like the connection is still good. Getting to that fuel pump on this truck is a pain.

Actually removing the instrument cluster is easier, so it is out of the dash right now (I was hoping the plug on the instrument cluster was disconnected, but it was not).

With the cluster out, can I check the gauge itself? (I would need to know which wires on which plug). Should just need continuity across the wires to the gauge, and it would be a good or not good correct? OR I could power up the + wire and ground the sending unit wire for the gauge to read full, correct?

Can I check if the sending unit in the tank is functioning from the instrument cluster plug? My mind is telling me I can do that, but it is blank on the procedure, CRS is kicking in. I do have a multi meter.

Re: Gas gauge on a 96 Dakota [Re: poorboy] #3266077
10/23/24 05:36 PM
10/23/24 05:36 PM
Joined: May 2019
Posts: 6,558
nowhere
S
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Sniper  Online Content
master
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Joined: May 2019
Posts: 6,558
nowhere
What I found online, https://servicingmanuals.com/cars/dodge/dakota/

Quote
Fuel Level Sensor: Description and Operation
CIRCUIT OPERATION
The fuel level sensor is a variable resistor. Circuit G4 connects the fuel level sensor to the fuel
gauge in the instrument cluster. Circuit F14 from fuse 14 in the fuse block supplies voltage to the
fuel gauge. The fuel level sensor draws voltage from circuit F14 through the fuel gauge on circuit
G4.
As current flows through the coils in the fuel gauge, it creates a magnetic field. One of the coils in
the gauge receives fixed current. The other coil is connected to the level sensor. The magnetic field
controls the position of the fuel gauge pointer.
The fuel level sensor contains a variable resistor. As the position of the float arm on the fuel level
sensor changes, the resistor changes the current flow through the second coil in the fuel gauge. A
change in current flow alters the magnetic field in the fuel gauge, which changes the pointer
position.
Circuit G8 from the level sensor connects to cavity C26 of the Powertrain Control Module (PCM).
Circuit G8 provides the fuel level input to the PCM. Circuit K4 provides ground for the signal.
Circuit Z1 provides the ground path for the fuel level sensor.


Testing

Quote
Fuel Gauge: Testing and Inspection
1. Place ignition switch in On position, then disconnect fuel gauge sending unit connector at top of
tank and observe gauge. Needle should move to
or remain at low end of scale.
2. Connect a jumper wire between sending unit ground cavity and gauge input cavity in body half of
sending unit connector and observe gauge.
Needle should move to high end of scale.
3. If needle performs as specified, replace fuel gauge sending unit; if not, proceed as follows:
a. Remove jumper wire and place ignition switch in Off position, then disconnect battery ground
cable. b. Check for continuity between sending unit ground cavity in body half of sending unit
connector and ground. If continuity exists, continue with
procedure; if not, repair ground circuit as necessary.
c. Remove instrument cluster and bezel, then disconnect printed circuit No. 1 connector 1 and
probe connector cavity H for continuity to ground.
If continuity exists, repair short as necessary; if not, continue with procedure.
d. Check for continuity between cavity H and gauge input cavity of sending unit body half
connector. If continuity exists, replace fuel gauge; if
not, repair open circuit as necessary







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