About 4 weeks ago, my fuel gauge really started lying more than a GM gauge usually does. I can use 10 gals of diesel before the damn gauge even begins to move past the "F" line.

Is there a fix?

Mine did that and the dealershis changed out the sender in the tank.
hope this will help.

I was hoping for a DIY fix....are there any out there?

I dont know if this will take care of it but on my 02 dodge cummins it would read empty with 10 gallons left. i took out the sender and wiped off the electric strip and its been good ever since

Would it be best to try this when the tank is empty or half empty?

(Just thinking of preventing an explosion for whatever reason, not thought of or known!)

Gas is flammable, Diesel is Combustible. Drop a lit match in a big pool of gas, and you are off to the burn unit, drop a lit match inot a pool of diesel, and the match goes out. Dont worry about the fuel in the tank lighting, it is the fuel you spill, that gets lit somewhere else, and burns back to you that you worry about.

Where is the sending unit at on these trucks?

It's In the fuel tanks you will need to drop the tank.

The GM sending unit consists of a wiper (brass type finger) that sweeps across a circuit board covered with a coating of a resistance-type metal plating. The continued sweeping (rubbing) of the wiper across the board wears through the coating, resulting in erratic gauge level indication. I've seen worse designs, but this particular one could have been designed with better durability in mind. The thickness of the coating is too thin and the contact patch of the wiper is too narrow for the tension it has, resulting in erosion of the coating, on the board, in a narrow area.

Is there a way to repair the sending unit and not have to replace it with a new one? My fuel gage has been inoperable for about a year now because I can't stand to part with the nearly $300 to get it working again. I may try taking mine out and cleaning it if I ever get a chance to see what that does. How difficult is it to drop the fuel tank on an extended cab?

Its much easier to pull the bed than the tank. Four nuts to remove the bed and wala. Don't have to drain or remove the tank.
Not as easy if you have a hitch in the bed, and it will depend on how the hitch is insalled. Try it, you'll like it.

Is there a way to repair the sending unit and not have to replace it with a new one? My fuel gage has been inoperable for about a year now because I can't stand to part with the nearly $300 to get it working again. I may try taking mine out and cleaning it if I ever get a chance to see what that does. How difficult is it to drop the fuel tank on an extended cab?
If your dealer really likes you, using your vin for a TSB search, there is a TSB with a PDF attached regarding fuel level senders. The PDF lists the float sender as a seperate part number, and IIRC, they were around $40. It is frustrating that the sender without the module cannot be looked up through the regular GM parts catalog, but that has been my experience.

Thanks heymccall! Now I've got to find that TSB!

This one says they got the whole shebang at carquest http://www.dieselplace.com/forum/showthread.php?p=2621491

And I think the TSB I'm referring to is listed halfway down this page http://www.nastyz28.com/forum/archive/index.php/t-22579.html

You are the man! With your help I think the TSB's I'm looking for are 040849019 and 3087 (updated part number for first TSB listed).

You are the man! With your help I think the TSB's I'm looking for are 040849019 and 3087 (updated part number for first TSB listed).
Now, decide how much corrosion lives under your truck. If it's quite a bit, purchase a sender module retaining ring before teardown. 1/2 mine were good and the other 1/2 very much rusted away. And, I'm pretty sure you'll need line disconnect tools to seperate the lines from the module.

Personally, I'd drop the tank, as every GM bed I've pulled has had several bolts frozen (rusted) into the bed crossmembers, requiring reengineering and fabrication to reinstall the bed.

i would pull the bed i do it all the time and have not have very many gm bolts froze at all in fact i can only remember a few you can have the bed set back and unit in and bed back on in a little over an hour and thats not busting you ass

For $300, I would gladly pay somebody else to mess with it, PITA!!

i would pull the bed i do it all the time and have not have very many gm bolts froze at all in fact i can only remember a few you can have the bed set back and unit in and bed back on in a little over an hour and thats not busting you ass
I, however, live in the rust belt:(.

I, however, live in the rust belt:(.


that is very true

I'm having the same problem. Anyone know the GM part number for the fuel sending unit for an 02. Also is there a differents between the smaller fuel tanks and the larger one? I have a 30 gallon tank.

x2 whats the part number

Anybody actual find a part # for the sending unit or fuel level sensor? I'm needing this for a 2002 Duramax.

and i need it for an 03 ccsb duramax diesel-ine..

pretty please,ill even put sugar on top..itz drivin me nuts!!!!

Google is my Friend

89060640

Sensor Assembly, Main Tank, Side

1999-2003

100200300 034353, C/K, 2 Dr, 4 Dr and Ext Cab Pickup

with LU3 or LR4 or LM7 or LQ4 or LQ9 or L18 and -- K53 (without robust fuel system)

Found here http://www.gm-trucks.com/forums/index.php?autocom=ibwiki&cmd=article&id=148

Searched using "04-08-49-018E"

For an '03 CCSB,
What is the exact part number?

For an '03 CCSB,
What is the exact part number?
Surely, you can have it looked up VIN at your stealer. That's how I verify.

I recently went to the dealer and discussed with the parts guy and the service manager, they both said that the unit in the tank is non-servicable, meaning that the whole damn sending unit, not the 50 dollar part, must be replaced when I asked how much...I almost sxxx.
$500.00 plus $300.00 labor...forget thet crap.
I will just use the DIC and make sure I dont use more than 25 gallons between fillerups.

I have a 05 lly cc 3500 4x4 and when mine is full It reads 3/4 tank and I was wondering about my oil pressure...it is low too..is there a recall or something on these models ???

I have a 05 lly cc 3500 4x4 and when mine is full It reads 3/4 tank and I was wondering about my oil pressure...it is low too..is there a recall or something on these models ???
Dmax's read low oil pressure. As a rule, 1000Rpm=20psi, 2000Rpm=40 psi.

Search "low oil pressure" on here for more on that.

My dealer is blaming my fuel gauge problems on my Astrostart remote starting unit. Along with any and all other electrical gremlins. Funny thing is that the Astrostart has been in the truck for years and numerous dealer visits without them ever saying a word. Now that the warranty is over and I'm having the same problems that I had before the warranty was over, they're telling me it's my remote starting unit and the fact that I spliced into the wiring harness.
I think they're wrong, but at this point they just refuse to work on my truck due to the Astrostart unit.
I guess I'm just going to live without an accurate fuel gauge and wonky seat and air conditioning controls.



Gar

My gauge is reading empty and lights up the low fuel indicator, when I've only used about 24 gallons (dually, so I have the larger tank). It used to go until about 28 or 29 gallons before it would do that.

With over 190k miles, the majority of which were under heavy towing (7-10 miles per gallon), that sending unit has moved a whole bunch of times. :o:

Not worth the money IMO, considering the DIC has been so accurate, within a half a gallon usually.

Okay fellas. I need some help finding the right part number for the fuel level sensor as well. According to the thread, the part number is 8906040; but I just called the chevy dealer and she said the P/N wasn't long enough. I had her look up the sending unit for my 2001 and she said you can't purchase the float level sensor individually for my truck. What's going on? I would really like to get a new float level sensor so my gauge reads properly, but don't want to spend $500 on a new sending unit.

I have a 2001 crew cab, (duramax of course). The last eight numbers of my VIN are 1F208665, which I was told is all I need to provide.

Please help.

Thanks!

Okay fellas. I need some help finding the right part number for the fuel level sensor as well. According to the thread, the part number is 8906040; but I just called the chevy dealer and she said the P/N wasn't long enough. I had her look up the sending unit for my 2001 and she said you can't purchase the float level sensor individually for my truck. What's going on? I would really like to get a new float level sensor so my gauge reads properly, but don't want to spend $500 on a new sending unit.

I have a 2001 crew cab, (duramax of course). The last eight numbers of my VIN are 1F208665, which I was told is all I need to provide.

Please help.

Thanks!Your PN should be 89060640;)

Your PN should be 89060640;)


Thanks for the help. I just tried a different dealer and they told me it couldn't be ordered seperate and you had to order 89060639 for $500. He said deisels are different than gas models and you couldn't just replace the sensor.
I was looking at one of your previous posts and it looks like you said something about the part not being listed under GM's normal part catalog. So I need to have them pull up a TSB; is that correct? How would they be able to pull the part number off of that? It sounds like I'll need to hold someone's hand to help them get me this part, so any additional info that you think would be helpful would be great.

Thanks!

I found the TSB you were refering to at the following webpage. I don't see were it mentions the diesel engine (LB7). Let me know if you are aware of another TSB that does include diesels. The TSB lists P/N 89060640, but I don't see the LB7 as a choice under this P/N

http://ww2.justanswer.com/uploads/Bluegorilla/2009-01-21_020718_99-04_fuel_gauge_update_sensor.pdf

Bump...really, no one has any other information or suggestions for me?

Ok here is the part number off of the box from the 3rd one i have just replaced all in the last 3 weeks. Now my truck is an 03 CC LB7. I only paid about $350 for the whole sending unit AND I have a Titan tank.

Now here is my problem. ALL of the sending units work outside of the tank as soon as they are installed we get a stuck fuel reading either empty, half full, or something else. It only happens when it is installed in the tank and buttoned up. We have had the tank dropped, I swear 5 times already. I am thinking its the wiring and when we are testing the unit outside the tank we are pulling on the wires thus making a proper connection and when it is installed and the wires are, for lack of a better term coiled, the connection is broken. The dealer told me the system works on a grounding principal. Meaning when the plug is disconnected, the fuel gauge should read FULL or zero ground. When empty the gauge is at full ground. So i am thinking a wire is broken between the harness and the connector from removing the tank on the first time around.

Any electrical thoughts here???

http://i100.photobucket.com/albums/m16/tf-ent/CIMG0111.jpg

If the gauge (and sender) works upon initial installation, maybe it's because your BCM is shutting down the gauge due to the fuel level changing slower than it expects. Many who have added a bed mounted tank experience the same thing.

If the gauge (and sender) works upon initial installation, maybe it's because your BCM is shutting down the gauge due to the fuel level changing slower than it expects. Many who have added a bed mounted tank experience the same thing.

and the cure? BCM??

http://www.dieselplace.com/forum/showthread.php?t=328318&highlight=titan+fuel

http://www.dieselplace.com/forum/showthread.php?t=244195&highlight=titan+fuel

http://www.dieselplace.com/forum/showthread.php?t=328318&highlight=titan+fuel

http://www.dieselplace.com/forum/showthread.php?t=244195&highlight=titan+fuel


OK from what I am reading here these post address the DIC issue not the gauge issue itself. What is the BCM?

This issue only came up because the Titan Tank developed a leak and needed to be replaced. After the new tank was installed is when this issue arose. only after the tank was changed did this problem start and develop.

OK from what I am reading here these post address the DIC issue not the gauge issue itself. What is the BCM?

This issue only came up because the Titan Tank developed a leak and needed to be replaced. After the new tank was installed is when this issue arose. only after the tank was changed did this problem start and develop.

Then ignore the above and find your broken wire.

I found the the 80960640 (other part # SK1208) at www.rightnowautoparts.com for $99. The whole package 89060639 is $280.

heymccall, you are an awesome asset to this site. Thanks for all your input!

I found the the 80960640 (other part # SK1208) at www.rightnowautoparts.com (http://www.rightnowautoparts.com) for $99. The whole package 89060639 is $280.

heymccall, you are an awesome asset to this site. Thanks for all your input!

Is this the correct part for a diesel? have you installed it? No problems? What year dmax are you dealing with?

Does anyone have experience with Delphi parts. Delphi part # FG0166 is the entire sending unit. I found a guy on eBay that is selling them for $75; for the whole unit. Are they high quality? Will it hold up? According to what I've read, it will fit and 01 Dmax.

Bump...still haven't taken care of this and thinking about diving into it. Anyone have any luck with either of the Non GM parts mentioned above?

Updated number for 89060639 is 19121637

Everywhere I look, including the local dealer, tells me 89060639 updates to 19121637 and is listed for gas trucks only.

Does anybody know for sure they will work in a diesel?

Bump

Has anyone used 19121637 in their diesels sucessfully?

Go to the nearest autozone, or checker auto, depending on where you live, THey only want 40 bucks for the sending unit. Im fixing mine this weekend, lifting the bed and doing it that way. It just clips onto the whole fuel sending unit.