Chevrolet Repair: 1997 Chevy Astro AWD intermittent stall / fuel gauge problem, chevy astro, gas gauge

Question
Hi. I would appreciate any insight you can provide for me to pass on to a mechanic.

I have a 1997 Chevy Astro AWD, automatic, (otherwise good condition) with the dreaded intermittent stalling problem.  Two mechanics found nothing, and no codes to indicate a problem.  It always stalls with my foot on the gas, and never sets the Check Engine light. It always starts back up, sometimes immediately, sometimes after a few minutes.  

Something new that may be a clue: The gas gauge read ¼ tank when I started out one day. I knew I had more.  The van stalled on this trip. At restart, it registered ¾ tank, but then moved around while I was driving.  I filled the tank (only 8 gal. needed) and it was okay the rest of the trip.  Next time (still full), it started moving towards ‘E’, so I turned it off and back on, and it registered a little higher for a few miles. I parked on a hill (nose up). When starting, it was reading ‘E’, stayed on ‘E’, and stalled within a hundred yards or so on level road. It took a few minutes to start.  The gauge was moving around as it drove, and it stalled one more time, but it did not seem to be on ‘E’ then (This time there was a ‘thump’ underneath, but it restarted immediately.)

The ‘check gauges’ and battery lights are coming on when it stalls.  Our driveway has a steep section, and I THINK I was parked on it (nose up) on each day it stalled. There is one time that I can’t remember, but suspect I was on the hill then too. The mechanic’s lot is flat, and he never got to it before it sat level all night. Not sure if that means anything. I can’t say for sure that it ALWAYS stalls after being parked on the hill, but it seems like that may be the case.   I don’t think it has ever happened after being parked level overnight. I'm going to test that tomorrow.  Thank you so much! -Cathy


Answer
Hello Cathy,
I would connect a fuel pressure tester to it, and leave it for a few days, so I could see if the pump was shutting off before it dies.

Sounds like there might be a loose ground connection in the wires from the fuel tank unit.
Check where it bolts to the frame, usually about under the drivers seat area.

Van