Broken wire inside fuel tank sending unit

[Rich Lambert]

It's the wire that goes into the little terminal clamps on either side of the plunger. I'm assuming this is one wire that's broken in half at the very bottom of the unit. Is this even fixable? If so, how is it routed on the piece at the bottom? Anyone have a picture of one with the wire intact?

I'd really like to fix this myself rather than shelling out $120 for a new one.

Invisible wires...

[Eddyvdw]

Here you go.
Mine has a slight problem though, the fuel warning light is on all the time....
Any suggestions?
Ed

[peon77]

Guys
I had the same problem and used this article to fix mine.Pelican Mini-Technical Article: Repairing the Fuel Tank Sending Unit

I had some wire in my garage that I took one strand from for a replacement wire. It ended up taking about 10 min to fix.

[Rich Lambert]

Ed & peon77, thanks for the replies and the pictures!

I replaced the wire, cleaned all the terminals, put it back in the tank, and the gauge is reading full, but I know it's not full.

Hmmm...does anyone know what the resistance readings should be for say, a half tank?

[86 911 Targa]

Originally Posted by Rich Lambert

Ed & peon77, thanks for the replies and the pictures!

I replaced the wire, cleaned all the terminals, put it back in the tank, and the gauge is reading full, but I know it's not full.

Hmmm...does anyone know what the resistance readings should be for say, a half tank?

Rich,

For our '86.

Gerry

[Rich Lambert]

Thanks Gerry. At least now I know what it should be.

For some reason the resistance is not changing as I move the float up & down and the gauge reads full. I took the sender completely apart, cleaned all the parts, re-soldered everything, double checked that everything's in the right place, and...no change. It worked perfectly before and the only thing I found wrong was the broken wire. I've tried 3 different wires of various gauges, but the outcome is the same.

I guess the next step is to find a local with a known good sender and go from there, hopefully eliminating the gauge as the issue. This should be such a simple thing and I've spent all day on it.

[86 911 Targa]

Originally Posted by Rich Lambert

Thanks Gerry. At least now I know what it should be.

For some reason the resistance is not changing as I move the float up & down and the gauge reads full. I took the sender completely apart, cleaned all the parts, re-soldered everything, double checked that everything's in the right place, and...no change. It worked perfectly before and the only thing I found wrong was the broken wire. I've tried 3 different wires of various gauges, but the outcome is the same.

I guess the next step is to find a local with a known good sender and go from there, hopefully eliminating the gauge as the issue. This should be such a simple thing and I've spent all day on it.

Rich,

Please be reminded that this is for our '86.

Your gas tank may be of different specification/capacity.

Good luck,

Gerry

[Eddyvdw]

Are you sure the long wire doesn't touch ground?
The risky bit is at the bottom of the sender (see picture).
Ed

[Rich Lambert]

Originally Posted by Eddyvdw

Are you sure the long wire doesn't touch ground?
The risky bit is at the bottom of the sender (see picture).
Ed

I routed the wire exactly like your picture.

[kahuna251]

Rich

i tried the same thing your trying the wire is very delicate i soldered new wire and physically it work fine until it went back into the tank
the olhm rating changes and the guage reads full (checked ground)
i purchase the new sending unit it took 7 minutes to install
the guage is fine and working

sometimes it pays to go new
2 hrs trying to repair it
7 minutes and $120 to install new
its a no brainer to me
new was better

bob

[john walker's workshop]

got a used one you can have. out of an '89.

[Rich Lambert]

Thanks John...I'll take it.

[santiaguito84]

Originally Posted by Rich Lambert

Thanks Gerry. At least now I know what it should be.

For some reason the resistance is not changing as I move the float up & down and the gauge reads full. I took the sender completely apart, cleaned all the parts, re-soldered everything, double checked that everything's in the right place, and...no change. It worked perfectly before and the only thing I found wrong was the broken wire. I've tried 3 different wires of various gauges, but the outcome is the same.

I guess the next step is to find a local with a known good sender and go from there, hopefully eliminating the gauge as the issue. This should be such a simple thing and I've spent all day on it.

Hello apology. Might you tell me what were the 3 types of wire you stole without success? in my country I can not pagarel cost of a new united. Nor can inmportar.