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Unread 07-18-2010, 09:10 PM   #1
Josh71NC
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1992 YJ Wrangler 
 
Join Date: Apr 2010
Location: Franklin
Posts: 11
YJ Fuel Gauge

Like most of you fellow YJ owners, my fuel gauge is spotty at best. When I fill the jeep up it has no problem reading a full tank, the gauge reads great until I get around a quarter of a tank. Once at a quarter of a tank, it randomly goes between three quarters and a half tank reading until I get pissed off and fill it up again. Its not a huge deal as I've dealing with it for a while now and I'm used to putting gas in nearly everyday. But as soon as I let my wife drive it alone, low and behold she calls me on the side of the road saying that my jeep is broke down... Empty tank... women never learn...

Anyway, what's the best way to diagnose this problem without yanking the whole *** end out of my jeep?

Many Thanks

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Unread 07-19-2010, 04:55 AM   #2
88YJGuy
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1988 YJ Wrangler 
 
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Maybe pull the gauge cluster out and clean the connections good, might help.
I did this to mine last weekend. Took the nut off and pulled the connection plug and sprayed some contact cleaner in the gauge holes. The copper traces on the mylar wiring conduit were a little oxidized too.

Gauge still bounces around a little, but I ran it down until it was bouncing around indicating (on average between minor swings) a 1/4 tank left- went to get gas and it took 12 gallons to fill it- so it seemed to be working in a general sense.

Maybe a better cleaning would've helped, as I was more concentrated on fixing the temp gauge, and just getting the gas gauge to read anything at all-it was stuck reading "E" all the time.
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88 YJ (Red) 2.5L, AX-5, NP231, Dana30/35 Posi-Lok, 4" RC Suspension, 1" Daystar Body, 33X12.50/15 BFG KM2's, Schrockworks Sliders. Vortec 5.3/4L60 conversion in the works.
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Unread 07-19-2010, 06:51 AM   #3
Roadyy
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1994 YJ Wrangler 
 
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If you are going to clean the card in the back of the cluster its best to take it completely off of the cluster and carefully straighten it out and clean it with alcohol and a q-tip and a pencil eraser works good too. Do not rub very hard causing damage to the coating. While you are at it go ahead and clean the center cluster card aswell to save having to do it later.
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Unread 07-19-2010, 06:59 AM   #4
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Quote:
Originally Posted by Josh71NC View Post
Like most of you fellow YJ owners, my fuel gauge is spotty at best. When I fill the jeep up it has no problem reading a full tank, the gauge reads great until I get around a quarter of a tank. Once at a quarter of a tank, it randomly goes between three quarters and a half tank reading until I get pissed off and fill it up again. Its not a huge deal as I've dealing with it for a while now and I'm used to putting gas in nearly everyday. But as soon as I let my wife drive it alone, low and behold she calls me on the side of the road saying that my jeep is broke down... Empty tank... women never learn...

Anyway, what's the best way to diagnose this problem without yanking the whole *** end out of my jeep?

Many Thanks
I fixed mine with a new sending until. its only 7 bolts to drop the tank. happy to walk you through it if you want.
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Unread 07-19-2010, 02:55 PM   #5
Jeremy93yj
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1993 YJ Wrangler 
 
Join Date: Apr 2010
Location: Ocala, FL, FL
Posts: 172
I fixed mine by pulling the sending unit and opening the small brown box that the float arm goes into. I cleaned the contacts inside then re-bent the tiny contact arm until the contact was touching through its entire arc of movement. You can test it with it out of the tank. Plug the sending unit into the wiring harness, turn on the key, and see the gas gauge move while you move the float arm. It took some trial and error to get the little contact arm bent just right, but I'm glad I did it. While you're in there, do the 20 gallon tank mod as well. Takes 15 seconds to do and makes life a bit easier. Good luck!
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