That full cast of 2014 Hemi Dodge Ram It's a 2500. It's got the Big Five, seven, uh, customer seats, engine light is on and a fuel gauge quit working and I've ever find all that is true? uh through the scan tool on it and it looks like we have a ton of codes in here. looks like the radio restraints HVAC About the only things that don't have codes. Uh, we're just concerned with the engine codes and we have a 463 fuel level sensor High So that tells me that it's probably open circuited.

He said he already uh, you know, threw a fuel pump at it but it didn't stick I guess and then okay. Instrument cluster implausible. Fuel level received I'd Be curious. um uh well let's see here.

which module is the instrument cluster? IPC I'm wondering if they're you know if we could just sweep the gauge just for Grins and Giggles Let's just see here if we can do that. Uh, let's see those are all telltales. Instrument Panel Self Test Let's go see issue. but I guess as long as if we can see the fuel gauge movement would be kind of neat.

but I don't think it's going to be an issue like I Say again that we have a high circuit code so there's that. Let me go to self-test here. let's see. take 30 seconds hit.

Okay, oh there we go. I Just missed it. It's going through uh, turning on all the telltales and then sweeping all the gauges. Yeah, there we go.

All right. Well that's good enough for me. We know that the you know fuel gauge isn't stuck, anything weird, which you know with that high circuit code it wouldn't be Anyways, we'll take them back out of that and then we will go right back into or we'll go into the engine controller here. But then at this point, um I guess we'll just have to look up a wiring diagram for it and see.

um I Can say he already threw a fuel pump at it which I assume had the level sensor on it. That'd be kind of funny if it wasn't there right? However, oftentimes do not come with a fuel level sensor. What you see here, we have a native head fuel level percent 16 it says uh. The thing is though, we have no idea how much fuel is actually in it and I assume this is a big assumption that there's more than 16 hopefully.

Uh, At any rate, let's see if we can do a bypass test on it somehow and see what we can figure out here folks. All right folks. I Got us some knowledge here. Got us a wiring diagram and a connector and a little bit of info I learned in service data.

Uh, pretty simple setup. pretty standard. Uh. field level sensor so it's a you know potentiometer signal wire ground wire going into the field level sensor.

uh coming from the body control module? uh, puts out a voltage. Um, you know in this wire here and then you know the signal return or the ground ground wire. There a couple things and note though I did read in service data on the actual signal Wire itself open circuited is 12 volts, full is one volt, empty is 10.5 However, the scan tool will interpret it as 0.6 Volts for full and 4.5 Volts for empty. So we can see right here it's at, you know, 4.98 So if you didn't know that and you only grabbed the wiring diagram, it went here and said whoa, this thing's got 12 volts on it.

you know you're seeing 4.9 Or if you know 5 volts on your scan tool, you might think something is up. So sometimes reading through service data you'll get these little handy bits of info. Uh, once this connector here you ask it is the only connector that's in line because I figure if we have to break the system down, that's the easiest way to do it. And they don't have a connector number but they call it the inline body chassis and that's what it's referred to as the inline body chassis connector.

and uh, the location of it is supposedly by the left front wheel. so in Prny snow plow truck dirt road driver. good place to start probably uh you know I'll think considering you know the guy said he uh you know like say shotgun his own fuel pump at it I think I've seen these connectors before on these trucks where they get rotted out. lots of wires in there.

Uh well. they have yeah, lock unlock, fuel pump control, license plate lights, yeah, trailer lights, cameras, all kinds of crap there. So I say we probably certainly I don't even know if we have to put it on the left. Grab ourselves a flashlight here and we can see if we can see that I think it lives behind the plastic? Yeah.

I think it lives behind this classic. So um yeah. I guess with that being said, let's uh, throw it up in here. It's gotta go up in here anyways because he's running some banana peels.

You want some other tires put on it? Put the truck up in here. obviously. use the mirror. uh, trying to figure out the best method.

we're gonna go right at the fuel sending unit, which is where we technically should start. It's kind of a pisser to get to. um I did look up on top of the tank and try to follow the wiring the best I could with the mirror. There's a spot where it runs under a cross member where it looks like the old harness is pinched in there, but it's in like a plastic track that looks like the factory.

It doesn't appear anything's out of line. The best: I could tell I can follow that wire back and do see that connector behind the front wheel here. and I think that because I got to pick tires off the vehicle anyways. I think we'll I'll peel the tires off, we'll get that connector and we'll do.

We'll see if we can just do our tests there real quick. Um, because like I say we're looking for an open circuit. we're not looking for a short we'll find I think it said pin six or check to see what we have at the connector on both sides. If we're good there, then we'll continue to go back and simply go do it this way because a that connector is way easier to get to than the top of the tank.

and B I've got to take the tires off anyways. yeah I just think it's barely tight. Yeah, just a little bit over finger tight. Yeah, whatever.

I'm thinking we pull out a couple. yeah, a little. Fashions Here, we'll just kind of tweak this back a little bit. Connector lives right behind here and instead of trying to fiddle up in there, if we can just expose it for the few screws it's going to take I think we'll be a lot further ahead.

There's like two more screws here, so I figured no sense to screw around. Let's take the rest of them out just to give it a little more loose. It's a bit stiffer than I thought it was going to be, that's what she said. but um.

I've been watching too much of the office lately. Foreign. Hopefully it's not all cruded out in there. It's a pretty good text connector.

I Just want to be able to do our testing here. Let's get a blow nozzle, get rid of some of the salt and sand here first, and uh, flipped it right behind and then then we'll find out which wire it is and see if we can't just probe it. but all this stuff here looks all pretty well. Factory So I think we're in good shape so far.

if I knock some of the dirt out of the connection. um I'm thinking probably instead of unplugging it right now, let's undo it. There kind of visual inspection. What? I Heard Pop Out was this little yellow insulator I was looking for the hole that it goes in I found it.

There's another one that's in here. kind of crooked. Also interesting that I was able to just blow it out with a blow nozzle being that it was on the bottom side. see if any of them are missing on the top at first glance.

I would say no. So I'm gonna. we're gonna have to put this back in I saved it I Thought that's what I heard pop out but I see another one that's in here all crooked and another one that's half hanging out. but it's hanging out.

but it's also covered with dirt like it's been hanging out for a long time. Not like we just popped it out, so that's kind of interesting. That one right there. you guys probably can't see it, but it's half hanging out.

but it's pretty well covered with dirt and just fits in there. Very. Loosely I Just pushed it in a little bit and there's another one down here. It's all kind of crooked in the hole, so that's interesting.

Um, okay, let's find out what wire it is. We'll probe it because we don't see any, uh, any green pus growing on the outside here. So let's find the wire and see what we have for voltage. So we're just going to be using just our standard voltmeter here and I'll probably just I'll just set it where I can see it.

We're going in pin five and six according to the diagram which is blue with white and black and they should be right next to each other near the end on the side that has six wires. Oh okay, yeah, right here. So um, blue with white and black. We will get a couple hypodermic back probes here.

We're not going to poke The Wire especially in this area. Lend it to work. What do we expect to see? Well, I'm expecting to see 12 volts because we are dealing with an open probe right next to the weather pack connector here. I Think it's in hard to tell sometimes when you're back probing a little back probe there.

Oh yeah, I'm lucky lucky and that's what we have this near battery voltage. of course it's dropping some voltage across a resistor. So what we can do from here? Well let's check it on the other side of this connector. the easiest thing to do.

you know we got good in. let's see if we got good hour. If we do, then we know we can keep motor in here. Quite a twisting it here.

Let me twist it this way. I'm gonna have to move my light so I can see and then because we have 12 volts on the front, we should have 12 volts on the back or close. you know, loosely. All right.

There's our black wire and then here's our blue with white I can't get in there 11.79 So same thing that we had on the front. Correct a little probe here and then we should be able to make this change on the scan tool 11.79 So same voltage here. We should be able. we can actually add a resistor in here if we wanted to and get our voltage to change and then see that change on the scan tool and you know, verify that everything works.

However, the good news is that we have our proper voltage here so we know we're not dealing with a connector that should be all corroded and cruddy now. I'm not too afraid to pop it apart now that we've gathered some data. All right, we are open. Uh, our open.

circuit must be further down the line, but when we're right here I want to check these? Uh, we got to put that yellow weather pack thing back in there and just make sure that there's no damage inside of here as a result of those other crooked ones. And everything in here looks super clean. so we're in good shape for the shape we're in and we can get the twist back out of this one. Let me get this yellow one put back in there, straighten out the other one that's kind of sitting in there crooked and then we're gonna keep on going that way.

So we're just going to hook in our right now. they're you know, shorted together. It's only got probably you know, 10 ohms resistance. Let me grab the scan tool, see if I can set that up there for you guys and then we can see it's at zero volts right now and as I increase resistance.

But oh, that goes pretty quick. So let's see here. I'm gonna slowly start increasing resistance and we can see that as I slowly add more resistance to the Circuit the voltage goes up and then you know I can just stop there so we can see that it, you know, obviously has a potential work. Why doesn't the fuel level percentage change? Uh I don't know.

It probably has some sort of balance module and has to have you know some algorithm for the calculation maybe a key cycle. But as we start taking resistance away and pull it back down more towards the short because remember, a short is not high resistance, it's low resistance and then we can add resistance to the circuit and get it to go back up so we know that the circuit has the ability to work. It is definitely open circuit and obviously, which we already knew. So let's keep following this down the line and see if we see anything.

I'm gonna I'm gonna kind of scrutinize the uh, the harness a little bit more where it runs along here. I'm going to blow out some of the dirt and stuff where it kind of covers it up and see if we see any green crusties. Um, that's about all we can do and if it comes down to it, we're going to have to. Okay, so I had it twist in it for a reason.

we're going to have to. you know, get to the top of the fuel tank to get to that connector. Even though this was the easiest one and I was hoping to find some green crap here, we didn't and we know it's good. at least to the back side of this harness.

You might have to pull driveshaft out to get to the top of the tank, so let's keep poking. So Iris comes down around. it looks pretty good through there. This one's on the back side of that mount up over the frame you always got watching where they go over the frame and stuff through there.

Oh I Thought it was kind of tight up there, down on the round and then goes up over the frame. eight is that the magical green dust? Uh oh man, be awesome here in the open. Let me see you guys down. That might be the gold mine right there or the green mines.

Whatever you want to call it mine, not mine. Um well. oh, you see if I can't feel? Oh, there's actually quite a bit of slack in this harness right there. Okay, that's such a big nose that is green.

Let's see it is. Yes, ma'am a little bit extra slack in this wire boy is today our lucky day or what. Oh, let's see if we can't reach up on top here. Get that retainer.

It's got a box right here on the outside of the frame so I can't uh, can't get it from the other side. There we go. Yes, ma'am broken right. Clean off so that's good.

Where does this go? Let's just do that plan. see if we've got all the extra wire that we can get to make our repair. There we go. Okay, better off having it down here anyways.

and so it looked over that frame. There's really no sense in it. It's kind of following this along here. Let me just found this so long.

There's really no sense for this to be ran outside because it really just Loops over and then Loops back over. So I say if we repair it, we just keep it in here. Oh look at that is this. Even the end of the tape? my whole weekend sucked.

But right now I feel like I'm living right. That must be because how often does that happen? The end of the tape you need to get to is right there. You find the broken wire and it's right in outer space right in the wide open. That's nice.

Looks like there's a couple wires here. rub through. We got this green with orange stripe and then we have the wire that we're looking for. the blue.

Curious to know what that other wire is? You know what else on this truck doesn't work that maybe the guy doesn't know about My razor blade is completely shot, but we just need to get past that point right here. Keep unwinding. Wow what a great day! What a great day! That one's junk I thought that one was but I don't think it hits I don't think I want to eat through and I might have to look at that with a magnifying glass. no I don't think it's through the insulation.

uh no, that's got a little Nick in it. Oh yeah, but I don't think it's through the insulation I don't know we might be better served just to, uh, chop it off just to be on the safe side. Even though it's not through right now. it might if it's got a little spot in it.

You know how things are in the Prny. There's that wire, All right. So we got that wire. We've got that wire and then this one will probably cut out just to be on the safe side.

Hopefully you guys got the bunny shot there. Rob you that kind of a little hitching. It's giddy up here. Yeah.

I wonder where that wire is green with brown or green with orange? Let me see if I can figure it out. They just have a light green with tan and a dark green with tan. Both of them are labeled as well. One's labeled as driver's secondary lock and the other one is labeled drivers secondary unlock I Don't know their functions because I didn't follow it any further than that.

So we're going to take chop it off. Strip them out. Boy, it's not too often. we gotta make a wire repair right out here in the wild, so that's pretty nice when that happens.

I'm gonna use everybody's favorite crimp and steel connectors aka the comet generators. What is that? I Don't know if we're gonna have enough slack in that blue one. We're probably not. Let's take and cut the black one so we can circumvent problem here.

Cut a little bit more out of it and then this blue one I Think we're going to be better off adding a bit of a length of wire because if we put a butt connector in there, we're going to be too short. it's going to be too tight on that wire and I still see a little bit of green in there. so we're going to take I'll just show you that probably? yeah, see how? that wire I can't see it and it's still green and it has all right. In case you didn't believe me, chop her down a little bit further.

we're halfway decent there. We're gonna have to go a little further. yet. that wire got the green in it.

Pretty good. Hopefully it didn't go real far off the wire. All right now. We're nice and shiny so we'll just add the length of wire between them here.

What is that? That's a little green there? All right, Shiny. Oh, it's scary. I Know it doesn't seem it uh on your guys then, but this has been quite a lot of process here. Must know it's not here today.

So I've been secretary, phone answer service, writer, estimate writer help Josh deal with all the bing bong, bing bongs and phone ringing and it's just hopefully it all seems cohesive in the end and everybody's happy. So we got a piece of uh 16 gauge blue wiring here we're gonna add in there, make sure that's about the correct length there is and when we do this, if the battery is not dead in the vehicle at this point, we should be able to see correct reading and assessment and how much fuel is in it. It's gonna be somewhere between half a volt and four and a half according to service data is that we sell good connections? Let's go C uh, where our voltage is at? Oh, hang on folks and we're at 1.2 volts and like I say I think this will populate uh, maybe during a key cycle. So uh, We've re, uh, re-established connections so we're good to go open.

I'm taking heat that up so all the adhesive comes out here and it kind of heat shrinks down on us and I'll just go through and do the rest of them I won't bore you with that process. All right, they're all cooled down and solidified. So now we will take our mini roll. So this, uh, test the tape wrapped around the socket to make a miniature roll because that tussa tape roll is really big and that would be the factory tape that they used on this.

So do this and nobody let ever know we were here except for you guys. Hopefully I Put enough roll on this tape. I Forgot how long this thing, what's across here? If not, we can add some more of course. Yeah, blue wire is a touch on the long side so that's okay.

foreign. Let me go get some more tape for us. This test of tape is really good tape. It's pretty abrasion resistant until it isn't.

You know it's better than regular electrical tape as far as that goes. I should say I guess in comparison and we're not going to run this back up over I can't really see the need to do it how it was. Let's kind of finish off our tape roll here. there's that okay and then I think what we'll do is we'll just kind of oh, we can just zip tie it right to uh, right to the fuel lines here and the brake line.

Looks like that's probably I don't know if that's evap. Oh no yeah. I know there's two brake lines and then the fuel line. or we could, you know, punch a hole in the frame and just use one of the zip ties with a Christmas tree on it.

Lots of options here that runs across the top like that. I Kind of see where it wants to sit here. naturally. kind of wants to stay down here.

I'm going to throw a zip tie around this fuel line I Want to make sure? Okay, it's got a wire tie right there against the frame. I Think if we do that, it's going to be fine. I Mean it's it's going to be better than where it was, that's for sure there. I think I'm gonna put one up in the corner of this canister.

There's an old dummy plug here I just don't want it rubbing through on this metal bracket on the canister over here and now we're gonna be in good shape. Oh ABS connector doesn't have any Christmas trees left on it. It's missing several Fasteners through here. Somebody's probably had it out before.

Maybe do manifolds or something, but missing some Christmas trees and all the facets down through the front. We put back what we took out, so that's it for now folks. Uh, pretty easy fix on this one. And it's a good thing that we looked in service aided because to be honest with you, if I just grabbed the wiring diagram and I seen the data on the scan tool, you know that zero to five volt interpretation or you know, five volts, that's where it was at.

I may have been led a little bit astray. Probably not because I've been doing it long enough. I would have seen 12 volts, especially when it was. you know, 12 volts or close to 12 volts and not actual battery voltage? Yeah, I Probably would have questioned it.

Probably would have just shorted it to ground with a test light see if we had change on the scan tool. but it is good to know information like that that the scan tool sees it you know as zero to five volts when in all reality the module the body module is sending out um, 12 volts. so that's good to know. Especially when you're you know, tracing down the circuit and you want to know.

uh High Circuit code can be open in the signal wire or an open in the ground. Either one of those two can be open if you, if you lose the ground, of course your signal wire elevates at that point and then if you lose your signal wire, it's essentially the same as using ground. voltage is elevated which is what we saw. we hadn't opened, uh, circuit or high resistance.

However, you want to look at it. high resistance and open pretty much the same thing. Open is the ultimate and high resistance. I guess if you think of it that way.

so that's it folks. Uh I want to think of you in a good way in that comment section down there, leaving a question in the comments, the concerns, uh, let me know how you guys would have found this one and uh, your process of of tracing down an open and splitting the circuit in half. We just started at the sending unit or started at the easiest connector to get to insty the Facebook You guys know where to find this and just remember viewers, if I can do it, you can do it. Thanks for watching foreign.