Is it possible to "fix" a fuel tank sender?

[Quickstep192]

My gas gauge hangs up at 1/2 tank. I'm pretty sure it's the sender and not the gauge. The needle will eventually fall below the half-way point, but the tank level at that point is usually below 1/4 tank. So, when the needle is at 1/2 tank, I never know whether I have a half tank or a quarter tank. Determined to fix it, I looked for a new sender, but after seeing the price, I'm wondering if there are any ways to figure out why it's hanging up and correct it. I've had the sender out and I don't see anything obvious. Any ideas?

[TRE Cup]

A sender in the 911,912,914 is constructed of a hollow tube that acts as protection and a guide for the float located inside of it. There are two very fine copper wires that extend from two different connections at the top and bottom of the tube.
The float makes the connection between the two wires. As it floats up and down , the electrical resistance changes. These changes are transmitted to the dash guage, to give you the level in the tank

So , what goes wrong:
1) The float gets worn out and some gas gets inside of it
2) The outer tube is compromised from compression < look for a dented gas tank near the driver side part of the tank
3) The glue/ crimping of the tube components fails allowing the tube to float free < this restricts movement of the float along the copper wires
4) The copper wires fail < does not sound that this is your case, as the fuel guage would not be accurate at all if a wire comes loose

Practicality of repair:
IF you can remove the outer aluminum tube intact with no dents< Remember the float needs a smooth bore to move up and down. THEN you are confronted with really thin wires for the float to rub against. You would have to source this wire, then figure out how to reconnect them at the correct length.
And again, is the float in good condition? If not, you won't find this unless you pick up a bunch of other broken senders.
So can you fix it yourself? Sure, given enough patience, steady hands, and available parts

URO recently sent us their aftermarket sender , to test, and it works like a champ, looks right too. I believe our host sells them now

[Ngrich99]

Originally Posted by Quickstep192

My gas gauge hangs up at 1/2 tank. I'm pretty sure it's the sender and not the gauge. The needle will eventually fall below the half-way point, but the tank level at that point is usually below 1/4 tank. So, when the needle is at 1/2 tank, I never know whether I have a half tank or a quarter tank. Determined to fix it, I looked for a new sender, but after seeing the price, I'm wondering if there are any ways to figure out why it's hanging up and correct it. I've had the sender out and I don't see anything obvious. Any ideas?

There is a small nut on the bottom that has a washer bent as a keeper. Tap that down and take the nut off. Then pull the assembly out of the housing. There is a float that rides on a center pole. Mine was stuck on this after sitting for 8years and the pole was no longer smooth. Use some carb cleaner and then fine grit sand paper . There are guide wires and some intact a on the float. Make sure they are clean and the wires are situated between the contacts. Mine works good now. Only pic I took.

[tdskip]

How much is your time worth?

Not being flip, possible vs time effective is a consideration if it isn't visibly gummed up.

Have you tried grounding the sender to confirm not the gauge?

[Alan L]

Mine has done the same. You can refresh them , pretty much as described above. If you do a search there are a couple of threads on it.
Alan

['78 SC]

When you remove the housing take photos and pay close attention to how the wires are routed. Be careful with the wires, they're probably not copper and not replaceable.
Lacquer thinner is excellent for cleaning the accumulated gunk. Also clean the reserve light contacts at the bottom of the sender.

[Quickstep192]

Originally Posted by tdskip

How much is your time worth?

Not being flip, possible vs time effective is a consideration if it isn't visibly gummed up.

Have you tried grounding the sender to confirm not the gauge?

Well, egg on my face. When I looked on the Pelican Parts site for a gas tank sending unit, the one I saw was the one for the 100litre tank which costs $500. Upon further review, I see one that's $150 which is more manageable. I still might have a go at fixing it if I can...