3rd Gen Fuel Gauge Issues

Ol'Blue

Ol'Blue

New member
Ok I know this is a hot topic so I'll keep it short and sweet.

We went through the hole system no kidding like 4 times and checked everything and still the gauge was crazy and would fall to E and flash. Finally pulled the Cluster AGAIN! and took it apart and really looked it over good. BOOM, Burned out spot in the board and also resister is shot which we found that is the last bit of testing we did on it and that gave us the final clue to the real issue.

SO that being said.

The good news is this- They can be fixed.

The bad news you can't get the parts from Toyota any longer so it went out to a rebuilder and well see how it dose with all this fixed.

I'll keep you all posted.

Blue
 
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Thanks for taking the time for posting your findings.
I'm NOT going through a fuel gauge issue right now but, it's good to know these tips when I do have a problem with my guage.
Interested if the resistor will solve your issue. GL
 
HiLife said:
Thanks for taking the time for posting your findings.
I'm NOT going through a fuel gauge issue right now but, it's good to know these tips when I do have a problem with my guage.
Interested if the resistor will solve your issue. GL
Click to expand...

I'm waiting for it all to get done and will be waiting for that same info also. He said it burned a hole in the board and he has fixed that but also fixing another issue in it. His work was cheap enough to try this first before getting a used one but I'm still looking for a back up also. This has been going on for 6 months and several trips to shops. I finally took it to a very good Electrical Diag guy and even he eat his lunch on this one. Happens some times when working on cars but they are making it right and no charge for all the drag and tear down after it was "Fixed"
 
Ol'Blue said:
I'm waiting for it all to get done and will be waiting for that same info also. He said it burned a hole in the board and he has fixed that but also fixing another issue in it. His work was cheap enough to try this first before getting a used one but I'm still looking for a back up also. This has been going on for 6 months and several trips to shops. I finally took it to a very good Electrical Diag guy and even he eat his lunch on this one. Happens some times when working on cars but they are making it right and no charge for all the drag and tear down after it was "Fixed"
Click to expand...
Wonder what caused the board to burn? A short some where in the circuit? Maybe a loose solder connection on the board?
 
There's a TSB about the fuel sender issues for certain years and it mentioned replacing the entire cluster with an updated part number. I'm guessing this was why.
 
gamefreakgc said:
There's a TSB about the fuel sender issues for certain years and it mentioned replacing the entire cluster with an updated part number. I'm guessing this was why.
Click to expand...

There is a TSB on this but mine was done at the factory. I did the update on this sender and also put a new pump and fuel gauge in the cluster while trying to beat this SOB lol.
 
HiLife said:
Wonder what caused the board to burn? A short some where in the circuit? Maybe a loose solder connection on the board?
Click to expand...

I'm really not sure. It's strange for sure. I remember it happening a long time ago and I thought it was the ignition but I never had any issues until not long ago with the gauge. So who knows what happened I'm just glad I finally found this dude.
 
Ol'Blue said:
There is a TSB on this but mine was done at the factory. I did the update on this sender and also put a new pump and fuel gauge in the cluster while trying to beat this SOB lol.
Click to expand...

And it didn't fix it? Dang, that sucks, your rig really is one of a kind lol! I've only dealt with the inaccurate gauge, which a little cleaning of the fuel sender unit help things out a bit.
 
gamefreakgc said:
And it didn't fix it? Dang, that sucks, your rig really is one of a kind lol! I've only dealt with the inaccurate gauge, which a little cleaning of the fuel sender unit help things out a bit.
Click to expand...

Nope, I did all the steps and it was still crazy. The first sending unit out of the box was bad too so I paid the labor twice to fix that and also a new gauge in the cluster but we missed the burned board and resistor the first time around too. So yeah it has been a royal PITA but I hope this will get her working as she should. Well see. I should get the cluster back today but I'm heading out of town for work so I will not know if it's good fora week or so. I'l keep everyone posted on this dude.

Blue
 
What year range had the issue?
I have a spare '99 manual cluster- if that would be of any help. The two lower tabs are broken, but you could repair it- or swap the housings.
Shoot me a message if it's something that could help you out
 
Ol'Blue said:
Ok I know this is a hot topic so I'll keep it short and sweet.

We went through the hole system no kidding like 4 times and checked everything and still the gauge was crazy and would fall to E and flash. Finally pulled the Cluster AGAIN! and took it apart and really looked it over good. BOOM, Burned out spot in the board and also resister is shot which we found that is the last bit of testing we did on it and that gave us the final clue to the real issue.

SO that being said.

The good news is this- They can be fixed.

The bad news you can't get the parts from Toyota any longer so it went out to a rebuilder and well see how it dose with all this fixed.

I'll keep you all posted.

Blue
Click to expand...
I've had the cluster fuel gauge issue, quick to nail down with a cluster swap to verify. I've got a few clusters in my hoarder parts stockpile which makes it easy.
 
Tyler James Inc said:
What year range had the issue?
I have a spare '99 manual cluster- if that would be of any help. The two lower tabs are broken, but you could repair it- or swap the housings.
Shoot me a message if it's something that could help you out
Click to expand...


The guy who fixed it had a 99 Cluster in the parts inventory, (he runs a really nice auto salvage yard, I would love to have two of the LS 6.0 engines that are in the show room ready to go into something) He pulled from that cluster to fix mine and only charged me 35 for the other cluster and I'll be getting that also.
 
Same thing happened to mine. Was able to solder it and fix it.

I beleive the trailer wiring burns it out some how. Mine burned out while towing, smoke came out of the dash and I saw some other threads about it.
 
DED&DED said:
Please post a link to the guy who fixes this problem--I have been trying to find him.

Thank you!
Click to expand...

Look up 43 Auto Salvage in Joplin MO

Ask for Miles. He rebuilds and fixes alot of the GM Clusters also and it helps having a full stock auto salvage yard also. This place is clean and well kept and ran. He has a few engines in the office and I'm not going to lie that LS 6.0 would look good in my 4runner lol.

Blue
 
Ol' Blue--I called Miles at 43 Auto Salvage.

He asked if I knew if your repaired board works. Please close the loop with him. I will mail the entire cluster to him after I make arrangements to pull it. Miles was great to talk to--obviously one smart guy. Thanks again for the lead.
 
Glad I saw this as I am having the same issue and I was about to have the fuel sending unit replaced.

Mine will drop to empty after I fill it up and the light flashes. When I get to about 100-150 miles driven on the tank, the next time I start it up it shows full until I fill it up again. It's like it shows empty when full and full when empty lol. Not sure if that was your exact experience, but mine has been doing this for years now.

Do you have any pics of the burned out spot on the board? Trying to know what I'm looking for before I take out the cluster.

Thanks for the info!
 
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