Help with 2005 Express fuel tank sensor...

[sscoulter]

Hello all,

I have a 2005 2500 Express that has a bad fuel sensor or sending unit. The fuel guage does not work at all and I have the "check engine" light on of course. I was told at Firestone the cost would be $1100.00 and the dealer wanted $700.00.

The tank does not look like it would be that hard to drop and I have a shop with the tools to do it. What do I do with the fuel lines? The appear to have some sort of "quick-connect" connections. Do these require a special tool or technique?

Is the sensor actually IN the tank or is it mounted on the front side toward the driver's seat?

Any advice would help me greatly.

Thanks in advance.


S

[sscoulter]

Originally Posted by sscoulter

Hello all,

I have a 2005 2500 Express that has a bad fuel sensor or sending unit. The fuel guage does not work at all and I have the "check engine" light on of course. I was told at Firestone the cost would be $1100.00 and the dealer wanted $700.00.

The tank does not look like it would be that hard to drop and I have a shop with the tools to do it. What do I do with the fuel lines? The appear to have some sort of "quick-connect" connections. Do these require a special tool or technique?

Is the sensor actually IN the tank or is it mounted on the front side toward the driver's seat?

Any advice would help me greatly.

Thanks in advance.


S

Anyone?


S

[DFBonnett]

The sensor/sending unit is in the fuel tank attached to the fuel pump assembly. According to the '04 shop manual, the quick connectors with the metal collar require tool J37088-A. The connectors with the plastic collar can have the plastic retainer release tabs squeezed by hand and the line pulled apart.

[MT-2500]

Before pulling the tank check for bad dash gauge or fuel sendiong unit.
Also check the 4 wire fuel pump connector on the transmission cross member.
Lot of connection/broken wire problems there on expess vans.
Also check the ground wires in connector there to.
A good quick test is with a bulb type test light.
Locate the fuel sending unit feed wire and key on and touch the wire with the test light.

It should light up dim and move the fuel gauge in dash.
If so the fuel sending unit is bad or wires to it.