1991 Dodge Ram Fuel Gauge Not Working

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FUEL PUMP MAN
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I recently replaced the fuel pump assembley (the whole unit -- pump, filter, float ...) in my 1991 Dodge Ram 150 (318 engine). I replaced it because the truck stopped while driving and would not start afterwards ... I dropped the fuel tank and simply removed the old unit and replaced it with a new unit by Master ... I took care not to damage the float when inserting the new unit in the fuel tank ... When completed the truck started but my fuel gauge does not work ... Before I start the truck the needle my set about 1/4 tank and after cranking the needle will float behind empty where it remains ... I think this was normal with the old pump but after cranking the needle would float to indicate the level of fuel in the tank ... The fuel gauge worked with the old unit ... I took the truck and filled it with gas hoping it would have some effect on the new float in the tank and make my fuel gauge start working but it still did not work ... Is there something I should have done or should do before I lower the tank and replace the new unit with the assumption that it is defective?
Nov 30, 2006 at 2:53 AM
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JDL
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Sorry for the late reply. I know this is an old post. In the future hope you don't have any vehicle issues, but, if you do, keep the site in mind. They are always working to improve the site.

When you install component, you have to be sure the float level arm is free to move up and down. Then check fuel level sending unit for voltage and ground. You may be able to use a couple resistors between the proper wire terminals for sending unit, with it unplugged. One resistor for close to empty, the other resistor for close to full, with key on, see if gage reacts properly to each resistor. If it does, then I think the problem is the sending unit. If not, check wiring circuit to instrument cluster, may be a faulty gage?
Dec 8, 2015 at 3:55 AM

Suggested Repair

Confirm the float arm moves freely. With the sender unplugged, check voltage and ground, then use resistors to simulate empty and full with the key on. If the gauge responds, replace the sending unit; if not, inspect the wiring to the cluster and the gauge.

Conversation Summary

After replacing the fuel pump assembly on a 1991 Dodge Ram 150, the truck starts but the fuel gauge stays near empty instead of showing the tank level as it did with the old unit. The expert advises verifying free float-arm movement, testing sender voltage and ground, and using resistors to see whether the gauge responds. A proper response points to a bad sending unit; no response points to wiring or a faulty gauge.

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