[truegearhead]

Originally Posted by thstone

I am stuck in fuel gauge hell.

If you remember, the gauge would never go above 3/4 even when the tank was full but would work normally between 3/4 to empty. Then the gauge stuck at 3/4 so I couldn't live with it any longer.

I've replaced the sending unit, made sure that the lines aren't interfering with the float, had the sender/gauge re-calibrated, checked the wiring from the sender to the gauge, verified that the sender is indeed sending the proper signal, and manually commanded the gauge using a tester - and the gauge is still stuck at 3/4.

This made racing last weekend quite interesting because I never really knew how much gas was in the tank except when I filled up completely. After the first race, I filled up completely with 7 gallons meaning that I finished the race with about a 1/2 tank or 60+ lbs heavier than I should have been.

The shop's conclusion this week is that the gauge itself has failed. A local instrument repair shop wanted $750 to repair the fuel gauge. Seemed like a pretty high price, I mean, that's almost a new set of tires to replace a circuit board (and yes, I value every financial transaction in equivalent sets of new racing tires these days). I declined their repair offer and ordered a used instrument cluster from eBay for $99 (including shipping).

Sure hope this solves the problem. I'll let you know what happens when I get the replacement cluster next week.

Did you solve this? This problem is caused by your fuel pump being rotated incorrectly and blocking the fuel level float. There is an arrow at the top of the housing showing the correct orientation.