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On a full tank, the gas gauge would only read 3/4 full. This has been going on for several years. Now, after more troubleshooting, it appears that oxidation on the contacts behind the instrument cluster was the reason that the gas gauge would only read up to 3/4 full even when the gas tank was actually full. I also noticed that depending on how you “seat” the instrument cluster in the dashboard can also affect the amount of electrical contact between the connectors and the printed wiring on the back of the instrument cluster. This could be due to damaged areas on the printed wiring. It has to be seated “just right”.
For example, after I filmed this video, I pulled out the instrument cluster again to adjust the shifter cable that clips to the steering column. When I reinserted the instrument cluster and tested it, the gas gauge showed only ¾ full (on a full tank)! Nooooooo!!! But when I adjusted the way the instrument cluster was “seated” against the connectors and tested it again, the gas gauge immediately read “full”.
Of course, the printed wiring is very fragile, and you have to be very careful handling the back of the instrument cluster. There is probably only a finite number of times that the instrument cluster can be removed and reinserted before the printed wiring fails. If that happens, it would probably require manually repairing the printed wiring with some other conductive material painted or spliced in its place.
Please add your comments below on any similar issues you encountered and any fixes (successful or not). Thanks very much for watching!
If you've been following this channel, you'll know that in prior videos, I replaced the gas gauge with a new old stock OEM gauge, and also replaced the fuel sending unit. Neither fixed the issue. I also did some troubleshooting in an attempt to diagnose what’s causing this, and had narrowed it down to a partially bad ground somewhere up at the front of the car between the instrument panel and the fuse box. For reference:
- replacing the fuel gage: • Replacing the fuel gau...
- replacing the sending unit: • How to replace the sen...
- troubleshooting the gas gauge problems: • Gas Gauge Problems - 1...
Other referenced videos:
- removing & reinstalling the steering wheel: • How to Remove the Stee...
- removing the instrument cluster: • Removing the instrumen...
- reinstalling the instrument cluster: • Reinstalling the instr...