DIY Video: Stop, Calibrate and Listen -OR- How to fix your spastic 3rd Gen fuel gauge

I'm curious as to how other people's gauges 'fail'. If some fail by being completely inaccurate or by flipping all over the place, that's one thing, but most (if not all) people I'm seeing complain on this issue seem to be saying that their gauge just drops too fast. So when they fill up when the light comes on, they only put 13-14 gallons back in, vs around 17.

While that's annoying in a way, I see it as a blessing, like Tim said earlier. It really just prevents you from ever running out of gas. I like knowing that when my light comes on, I have a good 5+ gallons (or about 100 miles, at an average of 19MPGs) or so to find a gas station. If I run out of gas, I deserve to walk several miles in the heat on the side of the road.
It also helps prevent running the tank too low and overheating the fuel pump, causing premature failure.

This is almost a literal example of a 'fail-safe'.

I don't know. Just my opinion. Cool that there's a 'fix' for this, but I can think of a lot of other things I'd rather spend $200 and a few hours of my time on.
 
Last edited:
Hey folks-
Like many other 3rd gen owners, my fuel gauge was funky. It dropped fast from full and the light would come on way too early, so I knew I wanted to do this repair. While I did find the two TSBs and some random info, I didn't see anything terribly conclusive so I decided to make a video of the fix.

Bear in mind this is my first attempt at a repair video so forgive the spelling and speech errors. I'm aware there are a few flubs. Also it doesn't show the process of unbolting everything and putting it all back together since I was filming by myself. It's more of an overview in order of events. Anyone with the parts and a little mechanical inclination can do this repair. A helper would be nice when lowering and raising the fuel tank but not absolutely necessary. Remember to work safely around fuel and under a car, and don't forget some safety glasses to keep the dirt out of your eyes! Also, you'll want the tank close to empty because a full tank or even half full would be quite heavy.

My vehicle is a 2000 so I did not have to replace anything in the gauge cluster like some other model years require, so that is not covered. The TSB will tell you what is required based on your VIN and the range it falls under.

Anyway, this was pretty easy and didn't take long, less than 2 hours taking my sweet time. Two people could do it in an hour easily. Parts were just over $200 total from Camelback Toyota. I do recommend getting a new fuel strainer even though it is not mentioned in the TSB. Mine was $10 at Oreilly. All other parts in this video are OEM. Part numbers are specified in TSB EL010-00.

TSB EL010-00 (PDF attached)

TSB EL010-99 (PDF attached)


I'm happy to report that the repair worked and my fuel gauge operates normally now. Best of luck!

Video here: https://youtu.be/uKAKBNYR5Jo

Justin :usa2:

Is it possible to mount the new level sender on the old bracket/suction tube assembly? From what I could see in the video it looked like the bracket assemblies were very similar and that maybe I’d be able to drill a hole in the old one and mount the new sender to that?

Thanks!
 
Not sure. You would need to get the length correct. You might have to actually get in there to find out for sure.
 
I've got all of the new parts going in today. Will report back after I get the truck back. Swapping the pump, sender, frame thing and the gaskets and valves.

I'm excited to have a useful fuel gauge again!!!

Also excited to see if she runs any better with the new fuel pump. Or at least starts quicker, I think the flowback valve was wearing out, or whatever that is called.
 
I've got all of the new parts going in today. Will report back after I get the truck back. Swapping the pump, sender, frame thing and the gaskets and valves.

I'm excited to have a useful fuel gauge again!!!

Also excited to see if she runs any better with the new fuel pump. Or at least starts quicker, I think the flowback valve was wearing out, or whatever that is called.

Make sure the calibration procedure is done after the install. If it doesn't give the correct tones turn the ignition off and try it again.

Good time for a new fuel filter as well if yours is due.

Hope it works for you.
 
Make sure the calibration procedure is done after the install. If it doesn't give the correct tones turn the ignition off and try it again.

Good time for a new fuel filter as well if yours is due.

Hope it works for you.

I actually changed the fuel filter back when I was doing my main refresh after I purchased her.

Yeah I forgot to print out the calibration sheet so I'll probably just do that myself. I don't think it matters as long as I do it asap right?
 
I actually changed the fuel filter back when I was doing my main refresh after I purchased her.

Yeah I forgot to print out the calibration sheet so I'll probably just do that myself. I don't think it matters as long as I do it asap right?

Yeah you should be fine it's just a final step. :thumb:
 
So... I see why she was reading crazy starting about 2 weeks ago.
Any chance this could have started a fire?

MhkVIzV.jpg
 
Sorry the vid is no longer up but I'm pretty sure mtbtim did a video on how to swap out the fuel sender. Should be the same repair in better detail.

Cheers,
Justin
 
Last edited:
Gas gauge Video still out there?

Hey folks-
Like many other 3rd gen owners, my fuel gauge was funky. It dropped fast from full and the light would come on way too early, so I knew I wanted to do this repair. While I did find the two TSBs and some random info, I didn't see anything terribly conclusive so I decided to make a video of the fix.

Bear in mind this is my first attempt at a repair video so forgive the spelling and speech errors. I'm aware there are a few flubs. Also it doesn't show the process of unbolting everything and putting it all back together since I was filming by myself. It's more of an overview in order of events. Anyone with the parts and a little mechanical inclination can do this repair. A helper would be nice when lowering and raising the fuel tank but not absolutely necessary. Remember to work safely around fuel and under a car, and don't forget some safety glasses to keep the dirt out of your eyes! Also, you'll want the tank close to empty because a full tank or even half full would be quite heavy.

My vehicle is a 2000 so I did not have to replace anything in the gauge cluster like some other model years require, so that is not covered. The TSB will tell you what is required based on your VIN and the range it falls under.

Anyway, this was pretty easy and didn't take long, less than 2 hours taking my sweet time. Two people could do it in an hour easily. Parts were just over $200 total from Camelback Toyota. I do recommend getting a new fuel strainer even though it is not mentioned in the TSB. Mine was $10 at Oreilly. All other parts in this video are OEM. Part numbers are specified in TSB EL010-00.

TSB EL010-00 (PDF attached)

TSB EL010-99 (PDF attached)


I'm happy to report that the repair worked and my fuel gauge operates normally now. Best of luck!

Video here: https://www.youtube.com/watch?v=uKAKBNYR5Jo&feature=youtu.be

Justin :usa2:

I clicked on your video link and it was no longer there...
I have the same problem. I was adding cameras to my rearview (added a fuse) and when I was done... Gas gauge read empty (I filled up the day before) and Gas light on. Don't know IF I DID SOMETHING (disconnected or shorted). Not sure if it was me or coincidence that it happened right then. Would love some help. [email protected] Not sure if I get alerts on the T4R.org. Thanks in Advance!!
 
Gas gauge Video still out there?

Hey folks-
Like many other 3rd gen owners, my fuel gauge was funky. It dropped fast from full and the light would come on way too early, so I knew I wanted to do this repair. While I did find the two TSBs and some random info, I didn't see anything terribly conclusive so I decided to make a video of the fix.

Bear in mind this is my first attempt at a repair video so forgive the spelling and speech errors. I'm aware there are a few flubs. Also it doesn't show the process of unbolting everything and putting it all back together since I was filming by myself. It's more of an overview in order of events. Anyone with the parts and a little mechanical inclination can do this repair. A helper would be nice when lowering and raising the fuel tank but not absolutely necessary. Remember to work safely around fuel and under a car, and don't forget some safety glasses to keep the dirt out of your eyes! Also, you'll want the tank close to empty because a full tank or even half full would be quite heavy.

My vehicle is a 2000 so I did not have to replace anything in the gauge cluster like some other model years require, so that is not covered. The TSB will tell you what is required based on your VIN and the range it falls under.

Anyway, this was pretty easy and didn't take long, less than 2 hours taking my sweet time. Two people could do it in an hour easily. Parts were just over $200 total from Camelback Toyota. I do recommend getting a new fuel strainer even though it is not mentioned in the TSB. Mine was $10 at Oreilly. All other parts in this video are OEM. Part numbers are specified in TSB EL010-00.

TSB EL010-00 (PDF attached)

TSB EL010-99 (PDF attached)


I'm happy to report that the repair worked and my fuel gauge operates normally now. Best of luck!

Video here: https://www.youtube.com/watch?v=uKAKBNYR5Jo&feature=youtu.be

Justin :usa2:

I clicked on your video link and it was no longer there...
I have the same problem. I was adding cameras to my rearview (added a fuse) and when I was done... Gas gauge read empty (I filled up the day before) and Gas light on. Don't know IF I DID SOMETHING (disconnected or shorted). Not sure if it was me or coincidence that it happened right then. Would love some help. [email protected] Not sure if I get alerts on the T4R.org. Thanks in Advance!!
 
Did a lot of research on this. Found that the older Trailer wiring harness's messed with the ground? Pulled the Trailer wiring harness off and followed this video to ground sending unit. Really easy. Fuel gauge works perfectly. Before it would stop at 3/4 or half tank and then drop suddenly when the tank got empty.

I followed this video on a 1999 4runner 4cyl.


https://www.youtube.com/watch?v=KNbMq7VvpdI
 

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