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Unread 04-07-2013, 02:32 AM   #1
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1991 YJ Wrangler 
Join Date: Mar 2009
Location: San Diego
Posts: 32
Fuel Gauge Problem

Hey guys. I'm having a problem with my 91 YJ (6 cylinder). I've done some research, but haven't quite found whats wrong.

I bought this Jeep not too long ago. The guy a bought it from did the 15-20 gallon conversion on it and said the fuel gauge worked fine.

The problem is that the fuel gauge always reads full when the car is on. If it is off, the gauge goes down to empty. And when I turn it on it goes all the way to FULL. The stranger thing is that when I fill up the tank, it reads all the way past the FULL line on the gauge. And then after a while it goes down to the FULL line. It never goes below FULL unless I turn the car off.

I have to carry extra gas and just reset my odometer every time I fill the tank and keep track of when I think I'm going to run out.

Any ideas of what it could be? Thanks guys.

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Unread 04-07-2013, 07:40 AM   #2
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1990 YJ Wrangler 
Join Date: Feb 2010
Location: Plymouth, MA
Posts: 66
Sounds like a bent/stuck float inside the fuel tank.
Depending upon where it's bent, it will ges stuck at that point... and it may have been bent by leaving the old float in while overfilling the tank due to the conversion which would also be the reason it reads overfull when you fill it up. It could go to empty when there's no signal coming from it (ignition off) but when ignition is on, it reads the level... in this case a false level due to the bend.
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Unread 04-07-2013, 07:58 AM   #3
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1993 YJ Wrangler 
Join Date: Jan 2005
Location: Albuquerque, NM
Posts: 6,490
... or the signal lead for the sender is not getting to the dash. You have a 'low ohms empty (0) and high ohms (90) full' gauge. That means an open wire will read full.
'93 YJ, '02 GM 4.3 Vortec V6, SOA, dual ARB's, 8.8+D30(w/WarnHubs), 4.88 gears, 35" BFG KM2's, AX15, 15x7 wheels, NP231+4:1+SYE+2LO, York OBA, Warn M8000, no top or doors Apr-Oct.
Member and Web guy: New Mexico 4 Wheelers My Truck Page on NM4W Site
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Unread 04-10-2013, 07:22 PM   #4
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1991 YJ Wrangler 
Join Date: Mar 2009
Location: San Diego
Posts: 32
A bend huh? That makes sense. Any hints on what else to look for when the tank is dropped?
And how could I check the amount of ohms? Where would I put the multimeter prongs to?
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