This is actually not too uncommon. There is a weak connection on the float arm for the level sensor in the tank. The factory method of repair is to remove the pump assembly from the tank, then snap the sending unit off the housing and install a new one. While it is true that will correct the problem, you do not need to get that involved.
Instead, there is a plastic finger you can bend back a little, then the float arm can be slid off. At the pivot end are two small metal tabs that are the movable contacts. Newer vehicles just have one tab. Simply bend those tabs out so they stick out another 1/16", then snap the arm back onto the housing. That puts more pressure on the contact so it makes a more solid connection. Those tabs are made of spring metal. They will spring back to their original shape after you let go of them, so you have to bend them further than desired so they will remain out further after they spring back. 1/16" is plenty for them to make a good contact.
The clue to this is the gauge will always read correctly when the tank is filled to a specific amount, and it always acts up when you have the same level in the tank. On the older minivans, the gauge would drop to "empty" whenever the tank was between quarter and half, and it would always read correctly at all other levels. I never did this repair on anything other than about a dozen minivans, but all the models use a sending unit of similar design.
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Tuesday, May 8th, 2018 AT 6:44 PM
