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Old May 23, 2010 | 10:08 PM
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Default 80 fuel gauge

I bought a 1980 last year in April and can't get the fuel gauge to read more than 1/4 tank. I tested the Gauge itself and it works the whole way up to full, I took the gauge panel out and everything seemed ok with the flex circuit board, I tested the sending unit and got some wacky readings so I replaced it to no avail. Any ideas?
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Old May 23, 2010 | 10:45 PM
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Willcox's site has the best gauge tutorial. You will find them on the left side of this page under Parts. It will show you step by step how to make the gauge work. mike...
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Old May 24, 2010 | 08:25 AM
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Have you tested (or cleaned/repaired) the electrical ground wire for the sending unit? If that has high resistance, the gauge readings will be in error.
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Old May 24, 2010 | 06:07 PM
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I ran an auxiliary ground wire direct from the gnd terminal of the sending unit to the negative battery terminal and the gauge reads the same, 1/4 full. The Corvette shop manual says the tank unit feed wire voltage should be 3-4 volts, I have 6.68 volts!

I am working on checking this willcox thing but I have to e-mail them as far as I can figure...
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Old May 24, 2010 | 06:10 PM
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I got the Willcox tutorial, it just took a while to download it...
thanks
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Old May 24, 2010 | 06:44 PM
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Pull the wire off the sender-gauge should go to full.
Ground the sender wire-gauge should go to empty.
If it does this the sender has a poor ground or is bad.
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Old May 24, 2010 | 07:01 PM
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I did pull the wire off and gauge goes to full, (both feed wire and gnd wire) same result.
I ran another ground wire to a good ground and still nothing. (Sending unit is new)
I'm going to look again at the ground nuts on the back of the gauge, I think I may have a bad ground there, thanks for your help!
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Old May 24, 2010 | 11:08 PM
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Have you recently been into the gauge cluster? If I remember correctly, there is a wire-wound resistor mounted to the back of the gauge terminals. Could it have been damaged or removed?
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Old May 29, 2010 | 09:52 PM
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As a matter of fact, I have had the gauge cluster out twice already and I did see this resistor, it seems to be in tact but I am thinking of checking it further or having it checked out. I also want to check the ground nuts on the fuel gauge itself so I am hoping to work on that on Monday.
Thanks again...
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Old May 29, 2010 | 10:15 PM
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The resistor in your 80 should be the ceramic type,make sure the side with the color is up.
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Old May 30, 2010 | 06:19 PM
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Your symptoms sure sound like the resistor on the gauge.

If the resistor is bad on the back of the fuel gauge, the highest reading it can make is slightly above 1/4 tank and this is only with a full tank of fuel. Check the resistor and if it is bad you'll need a 90 ohm to replace it.

The porcelain resistor is not available new or used but you can purchase a regular resistor from an electronics store and solder some loop ends on it. It will work just fine.

Willcox

Last edited by Willcox Corvette; May 30, 2010 at 06:22 PM.
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