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post #1 of 10 (permalink) Old 05-13-2019, 10:19 PM Thread Starter
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Gas gauge not functioning properly

Replaced fuel pump and sending unit now gas gauge at full only registers 3/4 tank. After a few gallons of previously full tank are used gauge registers reserve (1 malfunction) until next tank fill. Sending unit was warranted twice with no resolution. Any suggestions?
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post #2 of 10 (permalink) Old 05-14-2019, 04:14 AM
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What model sending unit and pump is it? These components were redesigned half way through the production run and the late ones are not compatible with your 02.

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post #3 of 10 (permalink) Old 06-05-2019, 11:14 PM Thread Starter
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Are you referring to the 4 pin - 5 pin issue?
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post #4 of 10 (permalink) Old 06-13-2019, 01:12 AM
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You can use your "trip" odometer to gauge how much gas is in your tank, if you can't get the sender fixed.. Fill your tank up.. Reset "trip" to zero.. at about 150 miles, your at around a 1/2 tank.. When you get to 300 plus miles... IT'S TIME TO FILL-UP AGAIN....
PS.. You can get a more accurate reading, if you calculate the MPG your getting vs the size of your tank..
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post #5 of 10 (permalink) Old 06-13-2019, 06:06 PM Thread Starter
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You can use your "trip" odometer to gauge how much gas is in your tank, if you can't get the sender fixed.. Fill your tank up.. Reset "trip" to zero.. at about 150 miles, your at around a 1/2 tank.. When you get to 300 plus miles... IT'S TIME TO FILL-UP AGAIN....
PS.. You can get a more accurate reading, if you calculate the MPG your getting vs the size of your tank..
Yes, Bobby that is how I have been doing it since this happened 2 years ago. I have tried EVERY tip or trick I could find on the issue. I usually gas up at 250 miles (12 gallons used - give or take). My frustration is that the shop didn't make good on finding the problem after the fuel pump and sending units were changed. I took it to the dealership due to frustration and they warrantied the sending unit twice to no avail and told me that they would have to go from the instrument panel to the sending unit to find the issue. It could take hours and at that rate I would be best to keep track of my mileage. Being a woman is a disadvantage when it comes to car issues.
post #6 of 10 (permalink) Old 06-13-2019, 06:47 PM Thread Starter
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Originally Posted by tjts1 View Post
What model sending unit and pump is it? These components were redesigned half way through the production run and the late ones are not compatible with your 02.
Are you referring to the 4 pin - 5 pin issue?
Mine was a 4 pin New one is a 5 pin

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post #7 of 10 (permalink) Old 06-13-2019, 08:45 PM
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If you have to replace the sender on a pre-MY2003 W203, and you go from a 4 to 5 pin, you have a "slippery slope" situation. You need a new rear SAM and a new instrument cluster. At dealer prices, you're probably looking at $4K+ for all this work. A really good indy could do it less than half that, but it means they MUST had SDS and KNOW HOW TO DO ALL THIS! They would install a used SAM and cluster. The used SAM is probably plug and play (or maybe some simple coding with SDS). The used cluster will need it's odometer zeroed which can be done with the proper 3rd party tools, or sent to a specialist for under $300 for that. Once its zeroed, SDS will see it as a new "virgin" cluster and allow it to be coded to the car and copy the odometer reading from the EIS (ignition switch).

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post #8 of 10 (permalink) Old 06-14-2019, 02:16 AM
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Being a woman is a disadvantage when it comes to car issues.
Yes, It's unfortunate that there are many "shops" that feel the need to rip off their customers.. Especially, the woman customers.. But you shouldn't feel like that you're being singled out..These same guys will rip off a man as fast as woman, if they think the guy doesn't have a clue.. (too bad for the younger generation, because they don't promote the teaching of "shop mechanics" in high school anymore)... So, it's really nice to see a lady, that's willing to do something to protect herself from all the crooks out there.. The best advice that one can be given is, " know what your talking about".. (or at least seem like you know what your talking about).. It might take some time, but you need to find a mechanic that is willing to let you supply your own parts and do exactly what you tell them to do.. My phone conversations with my guy, Grady.. Go something like is.. "Grady, Bobby here.. The starter on my Chevy van is crapping out.. what's the labor on the install of the starter that I'm going to drop off"... Or.. "Grady, what's the cost on doing a rear end swap on the Dakota, ... I've got a Durango rear end that I'm going to have shipped to you, Call me, when it comes in, so I can take a look at it, before you install it".. Grady, has never once tried to give me the "biz".. I know exactly what the cost are before he pops the hood.. And if there is a problem with the repair, IT'S ON ME.. because I'm the one who told him what I wanted done .. All that being said, it doesn't sound like anybody is trying to give you the "biz".. It sounds more like MB is the culprit here for not making a compatible pump/sender..
PS.. And you can't really blame MB for not wanting make a production run of 100,000 units, when there maybe only a market for less than 10,000..
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post #9 of 10 (permalink) Old 06-14-2019, 05:43 PM
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Bobby is right - most shops will take advantage of anyone who is not knowledgeable enough to call B.S. on them. But I do think they can be especially bad when dealing with women. It's unfortunate because I know a few women who are pretty good mechanics.

When I worked for The Marque and did some time at a dealership, I learned quickly not to judge a person by their looks - male or female. I worked in sales for about 3 months and one of my biggest deals was with a new SL55. One morning this guy was walking around the lot. He was built like a bouncer, and was wearing a dirty T-Shirt and holey cargo shorts. No one wanted to deal with him, so I did. He quickly tole me he was just there killing time with his buddy whose car was in service. We chatted a bit, i handed him my card, and forgot about it. A month later, I get paged with a customer on the floor. It's this guy. And he's there with his wife. Turns out he's a surgeon and decided to buy her an SL for her birthday.

Another sale I made was a nice lady who traded in her Lexus for a Mars Red C230. She looked like The Church Lady, but drove it like she stole it. Two months later, she came back to buy another one because she crashed it. Again, not at all what I expected when I first saw her.
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post #10 of 10 (permalink) Old 06-14-2019, 10:05 PM Thread Starter
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If you have to replace the sender on a pre-MY2003 W203, and you go from a 4 to 5 pin, you have a "slippery slope" situation. You need a new rear SAM and a new instrument cluster. At dealer prices, you're probably looking at $4K+ for all this work. A really good indy could do it less than half that, but it means they MUST had SDS and KNOW HOW TO DO ALL THIS! They would install a used SAM and cluster. The used SAM is probably plug and play (or maybe some simple coding with SDS). The used cluster will need it's odometer zeroed which can be done with the proper 3rd party tools, or sent to a specialist for under $300 for that. Once its zeroed, SDS will see it as a new "virgin" cluster and allow it to be coded to the car and copy the odometer reading from the EIS (ignition switch).
Well, I am half way there. I had to install a new rear SAM a few weeks ago. November 2017 a woman backed into me at the grocery and then took off (I managed to get her plate number). My trunk hasn't closed without extra pressure since the repair and I sometimes notice the trunk carpet is damp after a car wash. I should have said something right away but I didn't want to complain. The body shop missed something and moisture has been getting into the SAM. My son and I came out from a restaurant and the car would turn over but not run. I thought it was the fuel filter but after having it towed home I started checking the fuses because I could not hear the fuel pump engaging when I turned the key to the second position. I noticed corrosion on the fuel pump fuse and the relay. My insurance warranties the work for 5 years so as soon as the AC issue is fixed I will take it back to the body shop for the trunk leak. Now I just need the cluster...

It has been a rough few months, the home run going through my sun roof slider, the SAM and now the AC issue. I am considering a horse and buggy.
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