2005 9200 instrument panel malfunction

I will see if I can find anything more. The main engine harness routing is famous for chaffing in several spots between the passenger side firewall connector and the ecm itself. Check the harness as best as possible between the firewall and engine for any rubbed spots. Your datalink wires are numbered and coloured the same, but are actually a smaller 18 gauge wire outside the truck where they can be damaged easier. Another big problem is harnesses that are tied too tightly and crushed wiring, so check for tight wire ties or p clamps too. Are you able to check the engine and abs for any datalink or communication faults? Also disconnect your firewall and ecm connectors and check for any corrosion, bent or damaged pins, or pins that are partially pulled out. Reconnect with a good dielectric grease. Try to clean your cab to frame grounds, battery grounds, starter and alternator grounds, and the battery to frame ground too.

 

what other systems are you running on the truck, satellite communications, abs, automated trans, vorrad, and are you having issues with any of these? Like heavyd said ive seen trucks that were fleet trucks turned into used trucks and someone cut the satellite wiring on the back of the cab which causing big issues after the first time it gets wet. Even if you dont think you have it pull the power fuses and see what happens. Make sure to check all your firewall barrel connectors on both sides of the engine for water or corrosion.

 

Having the same problem.
View attachment 34101
'12 Prostar+, new floats.

 

Any gauge that point to 6 o'clock is a diagnostic indicator that the sensor or related circuit is bad. The fuel level sensor is monitored by the body controller which then sends the level to the cluster by a datalink. The datalink is ok, otherwise none of your gauges would work. You could try to plug another sensor in and see of the gauge fault clears.

 

Why I replaced the floats: the needle bounces around like a rubber ball, it's at 6 o'clock, now it's on empty, oh look, it's spinning around like a chicken that lost it's head. Thanks for that, I'll get the sensor's checked.

 

If your truck has dual tanks it should be the one on the drivers side that the body controller uses to feed the gauge. Prostars use a different system for fuel level sensing with two tanks. The right tank is only a storage tank and the left one is used to feed the engine. The body controller will monitor levels in both tanks and transfer fuel by a little pump from the right to the left tank as needed.

 

what made you replace the dimmer switch if dash lights were never showing any signs of malfunction?

 

Weird?????