My 2002 Dodge Caravan Sports fuel gauge is stuck on full. I tried hitting it with a mallet but that didn't work. I tried searching but noone had my exact problem, plus I'd rather get direct answers rather than reading everyone else's problems and solutions.

 

DIAGNOSIS AND TESTING - SELF-DIAGNOSTICS

The instrument clusters are equipped with a self diagnostic test feature to help identify electronic problems. Prior to any test, perform the Self-Diagnostic Test. The self diagnostic system displays instrument cluster stored fault codes in the odometer display, sweeps the gauges to the calibration points, and bulb checks the warning indicators. When the key is in the ON position with the engine not running, the MIL will remain illuminated for regulatory purposes.
To activate the Self-Diagnostic program:

1. With the ignition switch in the OFF position, depress the TRIP ODOMETER RESET button.
2. Continue to hold the TRIP ODOMETER RESET button until Sof and a number (software version number (i.e. Sof 3.2) appears in the odometer window then release the button. If a fault code is present, the cluster will display it in the odometer display. When all fault codes have been displayed, the cluster will display “end” in the odometer display. Refer to the INSTRUMENT CLUSTER DTC'S table to determine what each trouble code means. INSTRUMENT CLUSTER DTC'S
   
   DTC DESCRIPTION
3. 100.0 LOOP-BACK FAILURE
4. 100.1 ABS COMMUNICATION FAULT
5. 100.2 BCM COMMUNICATION FAULT
6. 100.3 EATX COMMUNICATION FAULT
7. 100.4 FCM COMMUNICATION FAULT
8. 100.5 ORC COMMUNICATION FAULT
9. 100.6 SBEC/DEC/MCM COMMUNICATION FAULT
10. 200.0 AIRBAG LED SHORT 200.1 AIRBAG LED OPEN
11. 200.2 ABS LED SHORT
12. 200.3 ABS LED OPEN
13. 200.6 EL INVERTER TIME-OUT
14. 200.7 EATX MISMATCH
15. 400.0 EEPROM READ/WRITE FAILURE
16. 400.1 IMPROPER POWER DOWN DETECTED

CALIBRATION TEST

The CLUSTER CALIBRATION table contains the proper calibration points for each gauge. If the gauge pointers are not calibrated, a problem exists in the cluster. If any gauge is out of calibration, replace the cluster.


CLUSTER CALIBRATION



SPEEDOMETER CALIBRATION POINT
1 0 MPH (0 KM/H)
2 20 MPH (40 KM/H)
3 60 MPH (100 KM/H)
4 100 MPH (160 KM/H)


TACHOMETER
1 0 RPM
2 1000 RPM
3 3000 RPM
4 6000 RPM

FUEL GAUGE
1 EMPTY
2 1/4 FILLED
3 1/2 FILLED
4 FULL


TEMPERATURE GAUGE
1 COLD
2 1/4
3 3/4
4 HOT


ODOMETER SEGMENT TEST

If a segment in the odometer does not illuminate normally, a problem exists in the display.
ELECTRONIC TRANSMISSION RANGE INDICATOR SEGMENT TEST

If a segment in the transmission range indicator does not illuminate normally, a problem exists in the display.

 

When the gauges do their self test, they will have pause points. If the fuel gauge passes the test, then you need to be looking at the sending unit. It may just have a worn spot on the resistor.