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Old 05-02-2011, 07:45 PM   #1
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Gas Tank sending unit

I'm having issues with my guage it seems. Filled up today and within 40 miles I was in between 1/2 - 3/4. I am assuming that because when I am almost empty and I fill up, I maybe get 10 gallons, not sure if I have the 15 or 20 gallon tank but assuming the 15th gallon, on E with 1/3rd left isn't right.

Is this a recurring issue by any chance? Any one ever replaced one?

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Old 05-02-2011, 07:55 PM   #2
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i think its pretty common to be on e when you have 5 gallons left. i think most tjs have the 19 gallon tank and a few had 15 gallons. i think if your sending unit was bad it would either read full all the time or empty all the time.

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Old 05-03-2011, 12:22 PM   #3
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Quote:
Originally Posted by Kevbz View Post
I'm having issues with my guage it seems. Filled up today and within 40 miles I was in between 1/2 - 3/4. I am assuming that because when I am almost empty and I fill up, I maybe get 10 gallons, not sure if I have the 15 or 20 gallon tank but assuming the 15th gallon, on E with 1/3rd left isn't right.

Is this a recurring issue by any chance? Any one ever replaced one?
I, too, am waiting for a new fuel level sending unit for my TJ--apparently they are on intergalactic backorder right now. Sending units can fail in numerous ways, though mine shares some characteristics with yours. Here is what mine is doing:

-At fill-up, the gauge goes all the way past F as expected.
-the needle then quickly plummets; by 80-90 miles it is at the half mark.
-at the half mark, there is a dead spot where the needle will drop below E and the light comes on. This typically lasts for ~10-15 miles.
-the needle then comes back up to half (and the light shuts off). Now it drops very slowly.
-after ~225 miles it will point to the 1/4 mark.
-now it begins dropping quickly; it points to E after only 250 miles. At this point, I typically still have another 4 gallons of fuel onboard. I have occasionally driven for a couple days with the needle below E and the light on; when I go to fill up, I still only can add about 17 gallons.

Since the fuel pump itself works fine, I've just been living with this erratic gauge behavior. I just keep an eye on the trip odometer to approximate how much fuel I really have.
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Old 05-03-2011, 12:36 PM   #4
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I believe the 2.5's came with a 15 gallon and the 4.0's came with the 19. Same tank just jeep stuck a piece in it so you can't fill it all the way on the 15.

When my gas gauge sits on the little pin at the bottom I have about 3-4 gallons of fuel left in my tank.
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Old 05-03-2011, 12:40 PM   #5
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The TJ's gas gauge is notoriously inaccurate which is caused by the sender mounted onto the fuel pump. The sender is commonly inaccurate without it just indicating full or empty. I replaced my fuel pump/fuel pressure regulator earlier this year and it comes with the sender. You can't easily replace the sender separately since it is spot welded to the fuel pump's housing. My gauge is now pretty accurate.
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Old 05-03-2011, 11:07 PM   #6
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Originally Posted by Sherpa View Post
-At fill-up, the gauge goes all the way past F as expected.
-the needle then quickly plummets; by 80-90 miles it is at the half mark.
Exactly...

From Full I will be at about 3/4 in about 35 miles, then it slows to somewhat normal mileage until just under a qtr. Then the way it hits empty you'd think it was pouring on the ground behind you. Have driven with the guage so far past E you'd think bone dry, then fill up and only take 11 gallons.
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Old 05-04-2011, 12:22 AM   #7
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I know I get close to two hundred miles per tank, I reset trip odo at fill up then drive till light comes on 170 or so, no need to replace , Quik ? Is the fuel filter built into sending unit an should I add a second one someplace for yearly p.m.
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Old 05-04-2011, 08:02 AM   #8
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Quote:
Originally Posted by Sherpa

I, too, am waiting for a new fuel level sending unit for my TJ--apparently they are on intergalactic backorder right now. Sending units can fail in numerous ways, though mine shares some characteristics with yours. Here is what mine is doing:

-At fill-up, the gauge goes all the way past F as expected.
-the needle then quickly plummets; by 80-90 miles it is at the half mark.
-at the half mark, there is a dead spot where the needle will drop below E and the light comes on. This typically lasts for ~10-15 miles.
-the needle then comes back up to half (and the light shuts off). Now it drops very slowly.
-after ~225 miles it will point to the 1/4 mark.
-now it begins dropping quickly; it points to E after only 250 miles. At this point, I typically still have another 4 gallons of fuel onboard. I have occasionally driven for a couple days with the needle below E and the light on; when I go to fill up, I still only can add about 17 gallons.

Since the fuel pump itself works fine, I've just been living with this erratic gauge behavior. I just keep an eye on the trip odometer to approximate how much fuel I really have.
I got mine from ebay, e7200m by airtex for 163 new. No back order and much cheaper than I could find it anywhere else. Double check the model number though as there were a couple of different set ups for tjs. Mine only fits 05-06. And don't break any lines!!!
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Old 05-04-2011, 09:10 AM   #9
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Originally Posted by Mijztif View Post
Is the fuel filter built into sending unit an should I add a second one someplace for yearly p.m.
The fuel filter is inside the fuel pressure regulator that sits on top of the gas tank. It has a positively huge surface area and is a lifetime fuel filter. No need to ever change it unless the Jeep is driven in a remote third-world country with dirty unfiltered gasoline.
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Old 05-04-2011, 03:52 PM   #10
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Quote:
Originally Posted by Jerry Bransford
The fuel filter is inside the fuel pressure regulator that sits on top of the gas tank. It has a positively huge surface area and is a lifetime fuel filter. No need to ever change it unless the Jeep is driven in a remote third-world country with dirty unfiltered gasoline.
Thanks Jerry, did not know that, so if changing sender unit leave filter alone, I like to check-rebuild-upgrade any items close to where I'm working,
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Old 05-04-2011, 04:42 PM   #11
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Old 11-08-2011, 05:19 PM   #12
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Quote:
Originally Posted by Jerry Bransford View Post
The fuel filter is inside the fuel pressure regulator that sits on top of the gas tank. It has a positively huge surface area and is a lifetime fuel filter. No need to ever change it unless the Jeep is driven in a remote third-world country with dirty unfiltered gasoline.
hey jerry really need help !!!!!! I had a 15 gallon pump in my 19 gallon tank , somebody really rigged it up .....my gas gauge unbenounced to me , was inaccurate , I ran out of gas thinking I had some gas left , goober that I am thought the pump needed to be changed , replaced it , it was only sputtering under load but now it wont even start , I thought it was injectors but wasnt sure checked them with my stethoscope , they were fine , checked the first cylinder plug , sure enough it was fouled ........pulling my hair out n screaming what do i do now???
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Old 11-09-2011, 12:08 PM   #13
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I just installed a new airtex fuel pump/sending unit. When I fill up, my gauge reads half way between 3/4 and full. Do not assume it will read perfect out of the box. I can live with the way it is. My big proublem was bad pump and check valve.
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Old 03-25-2013, 11:23 AM   #14
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I just installed a new airtex fuel pump/sending unit. When I fill up, my gauge reads half way between 3/4 and full. Do not assume it will read perfect out of the box. I can live with the way it is. My big proublem was bad pump and check valve.
You might have ordered the 19 gallon unit instead of the 15 gallon unit sounds like.
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Old 03-25-2013, 06:38 PM   #15
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Re: Gas Tank sending unit

My gauge only goes up to 3/4 full, even when it full. My light comes on after 125ish miles. I just watch my odor and fill around 185 miles driven. I'll eventually fix it, but for now I just watch it.
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Old 03-25-2013, 08:20 PM   #16
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I had the same problem with my 1997 Jeep Wrangler. I worked in the auto fuel system business and discovered the design is not linear. Just something we have to adjust to with Jeeps.
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Old 03-06-2014, 07:43 PM   #17
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I'm trying to figure out what size gas tank I have, Have it out of the jeep to replace skid plate if it ever warms up.Also having sending unit problems want to replace 1998 wrangler sport 4.0 engine. dont know what pump to buy 15 gal or 19 gal Thanks Tom

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