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TSB 08-33-94

Fuel Gauge Inaccuracy

Visit Geno's Garage for Truck accessories.

Date: Jul. 15, 1994

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-58-93 DATED DEC. 10, 1993.

Models: 1991 - 1993 (AD) Ram Pick Up/Ramcharger

1991 - 1993 (AD) Ram Pick Up/Ramcharger
1991 - 1994 (AN) Dakota

Symptom/Condition:

The fuel gauge my not read accurately. Customers way complain of too much reserve fuel in the tank when the gauge indicates empty or that they did not receive the larger capacity fuel tank they ordered.

Parts Required:

1991-1993 AN
   1    4761780    (15 gallon)    Sending Unit
         4761651    (22 Gallon)   Sending Unit
   1    4773164                        Harness

1994 AN (Built before 01-03-94, MDH 01-03-XX)**
   1   4773164                         Harness

1991-1993 AD
   1   4773164                         Harness

Repair Procedure:

This bulletin involves installing a wire harness that provides a common ground for the fuel gauge and the sending unit, and installing a revised sending unit on some models.

For 1991 through 1993 Dakota Only. (All other models proceed to step 2).

NOTE: IT IS CRITICAL WHEN INSTALLING THE NEW FUEL PUMP/SENDING UNIT TO MARK THE POSITION OF THE ORIGINAL MODULE TO THE FUEL TANK. WHEN INSTALLING THE NEW MODULE, ROTATE THE MODULE 1 INCH COUNTERCLOCKWISE FROM THE ORIGINAL POSITION.

1. Using the procedures outlined in the appropriate Service Manual, replace the fuel gauge sending unit with the appropriate sending unit.

FOR ALL MODELS:

2. Disconnect the battery.

3. Remove the connector from the fuel tank sending unit.

4. Remove the wedge lock from the connector being careful not break it.

5. Remove the terminal from cavity #2 (See Figure 1).

6. Insert the terminal from the harness, P/N 4773164, into cavity 42.

7. Install the wedge into the connector.

8. Install the connector to the sending unit.

9. Tie strap the harness along the chassis to the original harness following it into the engine compartment

10. Drill a 1/2", hole in the dash panel as shown in Figure 2.

11. Route the harness through the hole and seat the great.

12. Remove the knee blocker, the IP cluster and disconnect the cluster connectors.

13. Route the harness through the dash to the cluster area.

14. Remove the wedge from the cluster connector (See Figure 3) being careful not to break it.

15. Remove the terminal from cavity F (AN Body) or A (AD Body). (See Figure 3).

16. Tape the terminal back to the harness (See Figure 4).

 

Figure 4

17. Install the new harness terminal into cavity F.

18. Install the wedge.

19. Remove the IP ground nut (See Figure 5).

 

Figure 5

20. Install the harness ground eyelet and tighten the screw to 29 in. lbs.

21. Connect the cluster connectors install the cluster and knee blocker.

Notes:

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:
Labor Operation No:   AN   08-45-30-99 . . . . . . . . . . . . . . .  1. 9 Hrs.
                                   AD    08-45-30-99 . . . . . . . . . . . . . . .  0.7 Hrs.
                                             08-45-30-60 (with Skid Plate) . . 0.5 Hrs.

FAILURE CODE: XX - Service Adjustment