P0461 on 2020 Jeep Gladiator: Fuel Gauge and Sensor Performance Guide

What's Unique About the 2020-2020 Jeep GLADIATOR

For the 2020 Jeep Gladiator, code P0461 is not a random part failure but a well-documented issue addressed by two separate manufacturer Technical Service Bulletins (TSBs). One TSB points to a faulty fuel pump/level unit module, particularly in early 2020 models. [Bulletin #9004083] A second, more serious TSB for a specific build range requires the entire fuel tank to be replaced to resolve the sensor performance issue. [Bulletin #14-001-20, 1, 5] This makes it critical to check for applicable TSBs with a dealer before attempting any repair, as the fix may be covered under warranty.

Diagnostic Flowchart

Tap your situation to follow the diagnostic path that matches what you're seeing on this vehicle.

Symptoms You May Notice

• Check Engine Light is on
• Fuel gauge is inaccurate, fluctuating, or stuck.
• Fuel gauge may be stuck at 7/8 of a tank. [Bulletin #9004083]
• Fuel gauge may jump abruptly from one reading to another or flicker.
• Fuel gauge may read empty even when the tank is not.
• Low fuel warning light may be on or flashing even with fuel in the tank.
• Inaccurate "distance to empty" reading on the trip computer.

Most Likely Causes

1. Faulty Fuel Pump/Level Unit Module 🔴 High Probability → Shop Fuel Pump A known issue documented in TSB #9004083 for 2020 Gladiators with the 3.6L engine built before May 17, 2019. The fuel level sensor is integrated into this module, and early production units were prone to failure.
   How to confirm: A dealership can verify if TSB #9004083 applies to the vehicle's VIN. Owners report this as the common fix, often diagnosed after checking for wiring issues. 🎬 Watch an owner's experience diagnosing this P0461 error code.
   Typical fix: Replace the fuel pump/level unit module kit. Note that the original part number has been superseded.
   Est. part cost: $200-$350
2. Defective Fuel Tank Assembly 🟡 Medium Probability → Shop Fuel Tank A specific batch of 2020 Gladiators (built between April 12, 2019, and May 16, 2019) are subject to TSB #14-001-20, which identifies an issue within the fuel tank itself that requires full tank replacement to fix the P0461 code.
   How to confirm: A dealership must check the vehicle's build date and VIN against TSB #14-001-20.
   Typical fix: Replace the entire fuel tank and O-ring.
   Est. part cost: $700-$1000+
3. Wiring or Connector Issue ⚪ Low Probability While less common than the TSB-related failures for this model year, wiring harnesses can be susceptible to damage from road debris or corrosion, especially at the connector on top of the fuel tank.
   How to confirm: Visually inspect the wiring harness and connector at the top of the fuel tank for damage, corrosion, or loose connections. A mechanic can test for continuity and proper voltage at the connector. Dealerships report checking wiring before replacing parts under warranty.
   Typical fix: Repair the damaged section of the harness or clean/replace the connector.
   Est. part cost: $20-$100

Rare But Worth Checking

• Powertrain Control Module (PCM) Failure: → Shop Engine Control Module (ECM)

Diagnosis Steps

1. Read the trouble codes with an OBD-II scanner to confirm P0461 is present.
2. Contact a Jeep dealer with your VIN. Ask them to check for applicability of TSB #9004083 and TSB #14-001-20. This is the most critical step.
3. If a TSB applies, follow the manufacturer's recommended repair procedure (fuel pump module or fuel tank replacement).
4. Observe the fuel gauge. Note if it is stuck (especially at 7/8 full), erratic, flickering, or reads empty.
5. If no TSBs apply, the next step is a physical inspection. Raise the vehicle and inspect the wiring harness and electrical connector leading to the fuel tank for any signs of physical damage, corrosion, or looseness.
6. Using an advanced scan tool, monitor the live data for the fuel level sensor voltage. Look for irrational jumps, or a signal that is stuck high or low as fuel is used or added.
🎬 See a breakdown of P0461 causes and sensor performance fixes.
7. If TSBs and wiring are ruled out, the likely cause is the fuel level sending unit, which is part of the fuel pump module.
8. The final step is to access the top of the fuel tank to perform resistance tests on the sending unit itself or to replace the faulty component.

Parts You'll Likely Need

• Fuel Pump/Level Unit Module Kit (OEM #68723023AA (supersedes 68467807AA)) — This is the most common fix according to TSB #9004083 and owner reports. The fuel level sensor is integrated into this assembly. The original part number has been updated.
  Trusted brands: Mopar
  OEM price range: $250-$350
  Aftermarket price range: $150-$250
• Fuel Tank (OEM #68332305AC) — Required for vehicles falling under TSB #14-001-20, which identified a defect in the tank itself that affects sensor performance for a specific build range.
  Trusted brands: Mopar
  OEM price range: $700-$1000
  Aftermarket price range: N/A
• Fuel Tank O-Ring (OEM #55366298AA) — This seal should always be replaced whenever the fuel pump module is removed or the tank is replaced to prevent fuel leaks and EVAP codes.
  Trusted brands: Mopar
  OEM price range: $15-$30
  Aftermarket price range: $10-$20

Technical Service Bulletins (TSBs) & Recalls

• 14-001-20: Fuel Tank Replacement - P0461: Level Sensor Performance
• 9004083: MODULE KIT, Fuel Pump/Level Unit

Platform-Specific Known Issues

• TSB #14-001-20: Affects some 2020 Gladiators with the 3.6L engine built between April 12, 2019, and May 16, 2019. The prescribed fix for P0461 is a complete fuel tank and O-ring replacement.
• TSB #9004083: Affects 2020 Gladiators with the 3.6L engine built before May 17, 2019. It addresses P0461 and a fuel gauge stuck at 7/8 by replacing the fuel pump/level unit module kit.
• Part Backorders: Owners have reported long waits for the replacement fuel pump modules, sometimes lasting for months, though this may have improved over time. One owner reported a two-month wait for the part.

Mechanic-Grade Diagnostic Values

• Fuel Level Sensor 'A' Voltage (Live Data) — expected: A smooth sweep from approximately 0.5V (empty) to 4.5V (full).. Failure: Voltage is stuck, jumps erratically, or is outside the 0.5V-4.5V range.
• PCM Fuel Level Plausibility Check — expected: The fuel level sensor output must change by more than 3.5% over a 124-mile (200 km) drive cycle.. Failure: If the change in the sensor's output is 3.5% or less after driving 124 miles, the PCM detects a malfunction and stores the DTC.

Scan Tool Commands That Help

• wiTECH (OEM FCA/Stellantis Tool): Live Data Monitoring / Topology View — To monitor the 'Fuel Level Sensor A Voltage' PID in real-time while driving or rocking the vehicle to check for signal dropouts or erratic behavior. The topology view helps quickly assess communication status with the PCM and related modules.
• wiTECH or high-level aftermarket scanner: Instrument Cluster Actuator Test — To command a full sweep of all gauges, including the fuel gauge. If the gauge sweeps correctly during the test but reads incorrectly otherwise, it confirms the gauge itself is functional and the problem lies with the sensor or wiring.

Wiring & Ground Locations

• Fuel Tank Ground Strap — A strap connecting the fuel tank or fuel filler neck to the vehicle's frame or body.. Corrosion on this ground strap can cause erratic voltage readings from the fuel level sensor, mimicking a sensor failure. This should be inspected before replacing components.
• Rear Frame Grounds — Above the spare tire, there is a ground point on each side of the frame.. These are the closest factory grounding points to the fuel tank assembly and may be used by the fuel pump module harness. A loose or corroded connection here could cause this code.
• Passenger Kick Panel Grounds — Inside the cabin, in the passenger-side footwell area behind the kick panel. One of the three ground points is reportedly unused from the factory.. While further from the tank, these grounds are part of the body's main electrical system and could be relevant if diagnosing a complex wiring issue that extends into the cabin.

OEM Part Supersession History

• 68467807AA (and others) → 68723023AA — Update to address reliability issues with the integrated fuel level sensor that caused the P0461 code.
  Heads up: Part number 68723023AA is the latest revision and replaces a long list of previous parts, including 68413956AA, 68413956AB, 68413956AC, 68413956AD, 68413956AE, 68467807AA, and 68723022AA.