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Boricua21's Avatar
 
Join Date: Oct 2001
Location: Braselton, GA USA
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Stuck Fuel Level Gauge After Fill-up

My fuel gauge seems to be getting stuck on E for an increasing length of time (miles) after I fill up the tank. At first it would stay empty for some seconds and spring up to F (4/4). After that, it will correctly indicate the fuel level as it is used up. But now, it took 2 days for it to indicate correctly after filling the tank. Does this look like a bad gauge itself or is it some kind of sensor inside the tank that is stuck or going bad?

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Arnie Diaz
Braselton, GA
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1982 911 SC (3.2), Fabspeed Bypass and Muffler
2003 E39 BMW 530i (Daily Driver)
Old 09-19-2012, 09:23 AM
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The sender float is sticking. It is real easy on a 911 to get it out. I would wait until in is low on fuel and remove the sender. It is right on top of the tank. You will see where it is catching. Mine was an easy fix.
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Glen
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Old 09-19-2012, 09:46 AM
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JUst pull your float, very easy from the top of the tank, they tend to gum up. Easier just to replace it, get a new seal while you're at it.
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Old 09-19-2012, 09:47 AM
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The sender in the tank is sticking or the wiring is broken. To check: lift up the carpet in the trunk you'll see a round plate with a pair of wires turn your key on and ground the center wire while watching the gauge. It should 4/4 with wire disconnected when grounded should read empty. If that test is OK then the sender itself is getting stuck. remove inspect and clean. Look in the tank with a flashlight to inspect for rust.
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Old 09-19-2012, 09:47 AM
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Thanks guys, I'll check it this weekend and report back...
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Arnie Diaz
Braselton, GA
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1982 911 SC (3.2), Fabspeed Bypass and Muffler
2003 E39 BMW 530i (Daily Driver)
Old 09-19-2012, 09:52 AM
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I replaced mine when I thought the problem was the sender, turned out to be the gauge itself. My symptoms were different, needle would just drop like it there was no power. I still have it. New ones are $120. I'll make you a deal if it turns out you need one. PM me if interested.
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Old 09-19-2012, 10:50 AM
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I fixed mine recently after the sender stopped working. It turned out that during an autocross spin, the cylindrical part of the gauge shifted and would not move from 1/2. I took it apart as described, cleaned everything, made sure the float moved freely and easily, tightened up the electrical contacts that ride one the guide wires and it's been perfect once again. I would make sure that when you put it back together that you pay attention to the way the cap sits on the aluminum cylinder and that you crimp it a little into the plastic to prevent it from easily coming apart again.

Twenty minute repair, just do it when your tank is low to avoid messes, and do it in a well ventilated area!
Old 09-19-2012, 11:05 AM
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Just replaced mine, as well,....it was quite intermittent. I installed a new one (she had the original 23 year old one),..and tucked the old away to refurb later. I'm betting that the old one is repairable, after a nice clean-up,....but will still be relegated to the "original parts stock bin". Fuel level readouts are now accurate and much smoother.

It was "time"...

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Doyle
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Old 09-19-2012, 03:08 PM
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Bottom plastic piece fell off mine causing the outer housing to bind on float. Round pill bottle cap, washer and nut fixed it right up
Old 09-19-2012, 03:36 PM
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Just dissassembled my old one and cleaned it up considerably,..I may reinstall it to make sure that the travel is clean (as it now appears to be),..keep it as stock (still).

BEST!

Doyle

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Recording Engineer, Administrator and Entrepeneur
Designer of Fine Studios, Tube Amplifier Guru
1989 Porsche 911 Carrera Coupe
25th Anniversary Special Edition
Middle Georgia
Old 09-20-2012, 03:31 PM
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