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1996 challenger, fuel baffle question.

Minton33

New Member
I’ve recently picked up the boat and got it running and driving well, which took quite a bit, including having someone weld the cylinders up as they had froze and bust.

If you’d like to cut a long story short just skip to the last paragraph. I’d appreciate any help

Anyway I was trying to get the fuel gauge working last night. I jumped the wires going to gauge and it went up to just under full to which I thought okay good enough as long as it’s showing me something. checked the baffle and it was showing no resistance so I pulled it. The float seems to be fine. It’s the old black one, I put it in gas and it floated fine for an hour or so, although only the corner of it was out of the fuel and it was floating kinda sideways at an angle, so I’m not sure if it’s as floating as well as it should.

Cut into the baffle and it does not have an f1 fuse, looked all around, said screw it and cut into the other side and still no fuse. So I started checking continuity until I found where I lost it. At the very top above where the float stop is there is a decent sized black cylinder and it was not getting continuity through it from the circuit board to the wire. As I couldn’t really get to it since the float stop was in the way, I went to the back side of the circuit board and soldered a strip connecting both the terminal for the wire and the circuit board side of the black cylinder.

Put the float back in and it worked, resistance at empty is 89 and at full is 0.

So I plastic welded it all back up and hooked it up, with baffle upside down the gauge shows right under full, same as when I jumped the wires and with it empty it shows right below empty, so the gauge is slightly off.

I put it back in and for whatever reason even though it appears the tank is over 1/2 of the way full at least, the gauge is showing less than 1/4 of a tank. Probably about 1/8. Now I know that my gauge is slightly off but is this normal? I can see the tank appears that it would hold a lot more in the top half of the tank than the bottom so not sure if this would be correct or not. I’m wondering now if the float is still floating but maybe not floating enough to come all the way up?
 
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I’m really just wondering its normal for the gauge to show so low when the tank appears halfway full. The tank is a lot bigger at the top then at the bottom so just wondering if it’s normal or I’m still having a float issue
 
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