Defective Low Fuel Light/Warning

[sputnik40]

Had my gauge cluster replaced on recall a few months ago (2004 GMC Duramax). Found out Friday that the low fuel warning light/dash script does not work consistently. In a hurry running on vapors - but assuming I have some extra left as the light's not on - nope, ran out.

Rather than filling and priming to restart had it towed to dealer assuming they'd fix it and take responsibility for installing a defective part. Service manager observed that it didn't work consistently when I turned it in after hours. They look it over, mechanic says it should have 11 - 17% when the light comes on (about 4 gal give or take).

They don't do anything - charge me $95 (not to mention my towing bill) and send me on my way. Kinda ticked - wasn't in the mood to make a scene, figuring will go back thru management.

Anybody wanna comment - I know I was pushing some low fuel, but was kinda used to having that little yellow light work.

[86burgandyss]

In my opinion, if it is defective they should replace it!

[PULLING HAIR OUT]

I'm going through same problem. Dealer says I have to change the fuel pump because the sensor for the fuel gauge is on fuel pump. $1,000. Is this true?

[sputnik40]

Been traveling a bunch these past few months and put this issue off a bit - need to follow up. I'd say there's two methods for defection - either the cluster or the sending unit you reference. Apparently - the dealer tested the sending unit and it works - so I'm assuming it's the cluster, especially since my problem didn't occur until after they warrantied the cluster (e.g. defective part).

Background: I had the dealer look at it again a few months ago when I bit the bullet and had the passenger blower door replaced ($$$) - the mechanic said it was working fine, as the sender tested as operating. Since I purposely dropped it off on empty - I asked the write-up tech and the mechanic to prove it - walked out to the truck, started it up (the light flashed on startup - standard shows the bulb works I guess, and is tagged into computer), the gauge barely nudged up and the light did not turn on. So I said - if it works, how come the lights not on. They suggested that perhaps it had more than 5 gallons in it (see my prior posts on percentages) - so I drove 5.7 miles to the nearest station and pumped something like 25.4 gallons into it (capacity is just over 26 - so basically, not only did they fawke me over - they did it with the potential that I'd run out of fuel before even making it to a station).

Basically they suck - and I need to follow up with a letter (took dated pictures of the odometer before and after fill up - with time to coincide with dealer bill [about 15 minutes after paying] as well as the dated timed gas station receipts.

I did learn that GMC redid my prior posted percentages and dropped them lower - as many owners were complaining that the light came on too soon (e.g. 4.3 gal out of 26ish is too soon?). That'd be a good explanation - except my light never ever comes on - totally busted.

Let me know if you learn more - I keep spare vehicles so can drop off at the dealer, I just don't like being without my primary truck.

[TurboDog]

I don't have exactly the same situation, but I definitely have issues with that stupid yellow light. And I have run out of fuel about 500' from the gas station after the light came on about 1 mile ahead of that. I also have problems with it comming on when my tank is between 3/4 & full- which doesn't make any sense.

I'm pretty convinced that the problem (with mine anyway) is in the sending unit, but that the sending unit works fine in regard to flow & pressure. I decided the cost wasn't worth it & just set my trip OD everytime I fill up. This works for me because the miles don't lie, but that little yellow light is a lyin' son-of-a-gun.

Good luck with the dealship.