After changing the fuel pump last weekend, my gas gauge needle was going craze. It has been doing this for years, but got worse after the F P swap. I just replaced the pump, screen, and fuel filter, not the assembly. So today, I go to Big Boy Toys, our local RC shop, and get some diff oil. 10,000. That was plenty thick. I used the gas gauge from the Denali clustor, that I replaced, when I did that cluster swap some time back. I keep the old stepper motors, and my old cluster, so I started with that. I took apart the stepper motor, and drilled a small hole in the plastic case with a torch tip drill. ( Around $10 at your local welding supply store.) The diff oil was around $8. I had an overseas emergency kit with some syringes in it, that was given to me, when I worked offshore. So I picked what I figured would be about the rite size. After disassembling the stepper motor, and drilling the hole, I tried to pull the diff fluid through the syringe by poking the needle in the container of fluid. This stuff is thick. No luck there, so after a few tries, I pulled the plunger out and pored the diff oil onto the syringe. I put it about 1/3 of the way full, and replaced the plunger, flipped it over and bleed out the air. My hole was a little bigger than my needle so this gave a place for air to escape. I pushed the plunger very hard, ( this stuff doesnt flow easy) and put the indicator needle back on the gauge so I could turn it back and forth ti work the air out. Once the air was out and did fluid was oozing out of the hole, I slowly pulled out the needle, keeping the plunger pushed so that the void would be filled with fluid. After that, I cleaned up everything with alcohol. I had some plastic epoxy so I mixed some of that, and plugged up the hole. After about 30 mins, the epoxy was set up, so I reasemblied the motor, the cluster, and reinstalled it in the truck but without the clear cover over the gauges. I put the needle back to about where it was after starting the truck, but I left it loose, and went fulled up the the gas. It pegged full, so I pushed the needle in place. Once home, I put everything back together, oh and no more bouncing gas gauge needle. Here are a few pics.
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