Three problems related to other fuel system pump have been reported for the 1999 Chevrolet Suburban. The most recently reported issues are listed below.
The vehicle in question is a 1999 Chevrolet Suburban. The gas gauge read erratically and incorrectly for a number of months. Then the engine died immediately after I parked the vehicle one day and failed to restart. I determined that the fuel pump fuse had blown. A new fuse lasted 30 seconds before blowing in its turn. On removing the gas gauge sender/fuel pump assembly from the gasoline tank, I noticed that two of the wires were fused together. Separating the wires took some effort and revealed that the insulation on both wires had completely abraded where they contacted each other such that the bare wires inside touched each other and shorted out the circuit. The insulation on one of the wires had overheated and partially melted off the wire for a short distance (1/2 inch) from the point of contact. Replacement of the entire fuel pump/gas gauge sender solved the problem. Since the entire unit is located inside the gasoline tank of the vehicle, I am concerned that this short might have caused a spark that would ignite the gasoline in the gasoline tank. In the purple wire photo, one can see how the point of contact with the grey wire abraded the insulation down to the bare wire inside. In the grey wire photo, one can see both a comparable abrasion down to the bare wire and also partial melting of the wire insulation, to the point that additional bare wire showed. The metal wires do not appear to have melted or fused; only the insulation did that. But the insulation melting and fusion, as well as the two safety fuses that blew, argue that the abrasion of the insulation continued until the wires inside came into contact with each other. The entire unit is spring loaded such that it is in contact with both the top and the bottom of the gasoline tank. Since the tank flexes slightly in normal use, the wires flex as well, rubbing each other always.
Safety concern - no accident - 99 chevy Suburban fuel pump failure. I change the pump. When I looked at the old pump I noticed the hot wire to the fuel pump inside the fuel tank had insulation melted near the top connection. I disassembled the connection and found it had been arcing inside the fuel tank. I have the fuel pump is you want to see it. 9note: I sent a note to gm on the matter and only received a form letter e-mail in response).
1. Driving down the highway at 65 mph. 2. Fuel pump failed. Sudden power failure. My wife was drving and had a difficult time controlling the large vehicle and safely bringing it to a stop. 3. Replaced the fuel pump.