My truck is running out of fuel well before it reaches empty. When I first bought it (3 years ago), it would run out of fuel around the 1/8 fuel level. Now that I have done an engine swap it is now running out around 3/8 fuel level. Don't know why the change now?

I know the float is accurate since the amount of fuel was only 64 liters on the last fill (after running out at 3/8 tank).

I have a service manual and am assuming I need to remove the Fuel Pump Module to see what the issue is. It states I need a special spanner wrench #6856 to remove the module. The tool is $75 (google search). Is there an alternative? Or should I be looking elsewhere for a solution?

(I have attached a PDF of the Fuel Pump Module section of the service manual.)

Thanks

 

I've always used a screwdriver and a hammer to remove the cap. Gotta becareful not to chew it up though!
Maybe your float is getting stuck? Have you noticed your gas guage staying at that 3/8th's mark for longer than usual before running out of fuel?
Your sending unit could be bad as well with it's readings below 3/8ths of the tank.

 

Is the module an all-in-one piece with the inlet/suction hose encased to the module?
I don't want to tear it all apart only to find I have to replace the whole thing. If so I will find a replacement at the junkers first.

To remove Fuel Pump Module:
Using search on this forum found suggestions of using a large channel lock pliers or a dull screw driver and hammer off the module. (https://dodgeforum.com/forum/3rd-gen...-assy-out.html)

 

Is the float only used for fuel level readings? Or does it also effect where the fuel is sucked from inside the tank?

I know for a fact there is still fuel in the tank when running out of fuel, simply because upon refueling it takes far less then the tank size of 95 liters.

 

I believe the sending unit, float, filter and pump is all one unit.

 

Looks like I might have to find a replacement module from wreckers and simply swap it out.

I could live with it when EMPTY was at 1/8. But 3/8 does not give my much fuel. Major pain especially when I only get 10mpg. I need to carry a gerry can with fuel just to be safe.

Thanks for input.

 

Rockauto i believe sells fuel tank with pump n all for 188.00 if i recall, get it all new