Fuel Level Sender Wear

[gtc]

Here's a new mode of fuel level sender failure for the archives.

My fuel gauge has been stuck at 3/4 for a few weeks now. No amount of tapping the gauge or beating on the top of the sender would free it up. After searching here I figured that the wires inside the sender were probably dirty or corroded.
Well, tonight I removed the sender and opened it up. What I found, however, were 3 perfectly clean wires. This is what the float and wires looked like:


I slid the float up and down to try to see where it might have some dirt or corrosion on the wires, but there was none. It seemed to slide smoothly, but every fourth or fifth slide down, it would get stuck near the top of the sender - probably near the 3/4 tank level.

Upon closer examination of the float I noticed this:


The silver wires have worn grooves in the conductors on the float, and these grooves would periodically grab the wire and stop its motion. I tried to bend the brackets holding the wires so that the wires would ride on a part of the float away from the grooves, but there wasn't enough range of motion.

I suppose I'll just replace the sender next time it sticks

[euro911sc]

Very interesting... can you file it or use some emory paper to widen or remove the grove?

-Michael

[gtc]

It's such a tight space that it would be next to impossible to get in there to file or sand it down.
Since the groove has worn through the metal, I could only open it up in hope that it stopped catching on the wire. I suspect that a new groove would form relatively quickly.

After my first fill up, the sender has stuck at about 1/3 of a tank. I think I'm going to break down and purchase a new one.

[lhoudyshell]

gtc, it is a tight space, try an emory board or an old points file. Lynn

[dshepp806]

damned dood shots! Thanx!!

Doyle

[Wyvern]

Seeing you photos inspired me to remove and check out my sender ...

Mine would bounce fro actual level to empty on just about every bump in the road.
Has always done this ...

I had my SO tap the top of the sender and that duplicated the issue.

Pulled the sender and took off the outer tube.

On one side the wire had jumped off track to not weave between the contacts correctly.

Carefully threaded it and cleaned the contacts and wire.
With a small plier I bent the "holder for the wire to put a bit more tension on it.
Perhaps that will stop future issues.

installed and test drove ...

works great no issues. thanks for the insight and inspiration.

1/2 hour of time , working instrument and , 0 $