Gas Gauge Says Empty 2003 Adventurer (Workhorse Chassis)

[DavidH477]

I have a 2003 adventurer 35ft workhorse w22. The gas gauge says empty and the low fuel message stays on. I did the cluster test and the needle moved from 0 to 50 to 100. I’ve seen comments about testing the wires going to the sending unit and I’m curious if that will require dropping the tank. If I’m dropping the tank anyway, I’ll just replace the fuel pump regardless.

Does anybody have any other trouble troubleshooting tips? I have three cans of seafoam in the tank right now, they’ve been there for about two weeks. I went around yesterday and smacked the tank with a rubber mallet. I think I’m going to resurface the ground connections near the fuel tank next, and maybe check fuses? The hilarious part is that I thought the tank was empty, so I filled it all the way up ��

 

[creativepart]

Your best best is to ask for help on IRV2’s Workhorse chassis forum:

https://www.irv2.com/forums/f22/

 

[DavidH477]

Your best best is to ask for help on IRV2’s Workhorse chassis forum:

https://www.irv2.com/forums/f22/

Started a new thread over there. Thanks!

 

[HappiHenri]

What is your mileage?
Workhorse fuel pumps don't last much more than 70k miles. My guess to your problem is a dying fuel pump.
I had to replace mine in my 2005 Adventurer at about 75k, but only after many check engine lights and poor uphill power. Installed a fuel pressure gauge in order to see my pressure down to 40 psi - should be 60.
Following 3 -4 great videos by Kevin Caudill on YouTube I partially dropped tank using his 4 corner method in order to access fuel pump. Made sure to replace with an OE Delphi pump ( watch his videos to see why). Big job but pressure back to 60 and engine runs great.

 

[DavidH477]

What is your mileage?
Workhorse fuel pumps don't last much more than 70k miles. My guess to your problem is a dying fuel pump.
I had to replace mine in my 2005 Adventurer at about 75k, but only after many check engine lights and poor uphill power. Installed a fuel pressure gauge in order to see my pressure down to 40 psi - should be 60.
Following 3 -4 great videos by Kevin Caudill on YouTube I partially dropped tank using his 4 corner method in order to access fuel pump. Made sure to replace with an OE Delphi pump ( watch his videos to see why). Big job but pressure back to 60 and engine runs great.

88k miles. Thanks! I plan to replace the pump soon. I have one trip next week, totaling about 500 miles. I’m hoping to get most of the fuel out of the tank during that trip, and I have a mechanic lined up already to replace the pump. I haven’t bought the replacement yet, so I’ll look into the Delphi you suggested.

 

[HappiHenri]

David - Here are some links to the Youtube videos I mentioned. Kevin Caudill has a 2006 Workhorse chassis, and has produced dozens of great videos about various repairs he has done. Several years ago he did a series on a fuel pressure gauge, OE vs aftermarket fuel pumps, and fuel pump replacement. Suggest you and your mechanic look at these.

Fuel Pressure Gauge for Workhorse 8.1l engines:

Fuel Pump comparisons:

Fuel pump replacement in Tank: (GREAT Information!)