Gas Gauge Problems on 97 Grand Caravan Sport

[E. Reed]

It started a couple weeks ago...when I'd fill up the tank, it would
show about 1/8 tank less than full. I filled up the tank yesterday,
because the fuel warning light was on and it was showing about 1/8
tank remaining, and the gauge has remained at 1/8 tank with the light
on! Tried shutting down the van, re-starting, etc, but it still shows
the same.

Any good ideas on what the problem is? The gauge?...something in the
tank?

Thanks!

E. Reed

 

[Eric May]

It started a couple weeks ago...when I'd fill up the tank, it would
show about 1/8 tank less than full. I filled up the tank yesterday,
because the fuel warning light was on and it was showing about 1/8
tank remaining, and the gauge has remained at 1/8 tank with the light
on! Tried shutting down the van, re-starting, etc, but it still shows
the same.

Any good ideas on what the problem is? The gauge?...something in the
tank?

The fuel level sensor uses an etched pc board and a sliding contact
(attached to the float arm) to measure fuel level. The etchings wear out far
too soon (IMHO) and cause the loss of contact (infinite resistance), which
makes the gauge read empty and activates the light. Usually there are bad
spots where the gauge and light seem to go crazy, but then it clears up when
the sliding contact moves to a good spot. I was able to live with the
problemm for a fairly long time because the bad spot began at about 3/4 tank
level and ended around 1/2 tank level. It cleared up when it counted . . .
at lower tank levels. However, the bad spot kept growing, so I replaced the
sensor. Not a difficult job, but messy.