The gas gauge sender is spot-welded onto the fuel pump housing. Not even sure if the sender itself is still available, I don't think it is. The problem could just be from the connector that is on the front driver's side corner of the gas tank. Try reseating the connector a couple times, it is for both the fuel pump and fuel gauge sender.

 

Thanks Jerry for the quick reply....will give that a shot!☮

 

Jerry’s advice has always been the best for me. If you end up needing to replace the fuel pump and sender, the part is easy to find at places like rock auto or even a local parts store. One other thing to check/replace in the process is, the armor for the fuel tank. The only way to replace it is to drop the fuel tank, and the only way to replace the fuel pump/sender is to drop the fuel tank. It’s a pretty easy process.

 

Thanks for your reply....it does look like a pretty easy process. Hardest part will be running my tank down low enough with no gauge without running out of gas first! 😁

 

Brother, you have a jeep! Emptying your gas tank will be no problem! 🤣😂🤣

 

I first want to say that Jerry’s advice is always spot on so I’m not trying to contradict him, but I was having issues with my float (erratic gauge) and was gonna try to just replace that part of the unit, but I didn’t want to do it twice if and when the pump took a dump, so I bit the bullet and replaced the pump and float together. I have a 98 TJ with over 300k miles so I figured it was just a matter of time… I believe I got the unit from orileys for around 150 bucks.

 

I have replaced just the fuel gauge float assembly. In my case the resistor board was worn through. I don't recall it being welded in place. I definitely didn't weld it back on. I thought it clipped on, but I really don't remember. Maybe the design was modified since production.

I would have to look through my records to figure out what I bought, this is just an example:

Herko Fuel Level Sensor FC59 for Jeep Cherokee Grand Cherokee Wrangler TJ 97-04

If the pump and the rest of the sending unit are good, I would leave them alone. Should you decide to replace them, last I knew you can not buy the full OEM Bosch unit, but the pump only came back into production.

 

Thanks man! I have bookmarked that shopping link.....not sure what I am going to do yet....kind of tough when I am not sure exactly what fuel pump is in there right now...The last owner really gave me a lot of service history papers from over the years he had it (2nd owner)...I made a spreadsheet from them but the fuel pump is one of the few I was not able to find any papers on ...this TJ has had so many replacements over the last 25 yrs that on one hand it may be sort of a good thing that a lot of stuff is relatively new comparatively...but then on the other hand can make it tough knowing exactly what is what

 

Old post. But if you're dropping the tank it's idiotic NOT to replace the pump assembly.

 

X 2.

 

td4abb, why not post up the final results, assuming all is final, for others in the future.

also, a few years ago when i needed to drop my tank for an evap code, i drove around with a 2 gal gas can in the back. granted my fuel gauge worked, as well as any TJ gauge, but just in case. i timed it just right, when i did drop the tank probably had less than a half gal left, never used the gas can.

 

as of now i do not have results for this project to share ….. there have been too many pop up issues that were more pressing in terms of drivability so this one is still on the to-do list…which as Jeep owners we know never really gets marked complete!