Fuel Level Sender & Gauge Wiring for '92-96 Broncos ('87-91 Bronco similar)
IF THE IMAGE IS TOO SMALL, click it.
For '87-96 F-series w/dual tanks, see:
ERROR: C251 pin 5 should read "Fuel ResEt Indicator Input", but that circuit is not present on most trucks, and not used on any. There may be other errors or variations due to model year changes & optional equipment.
Sender Range: 160 (full) - 16 (empty) Ohms
A gauge that pegs past full indicates an open circuit on the Y/W wire (broken wire; unplugged connector; corroded terminal; varnished sender; F-series - selector switch or connector faults).
A gauge that pegs past empty indicates a short to ground on the Y/W wire (pinched to the frame, body, or dash supports), a fault in the gauge or its power or ground from the film circuit, OR a sunken float.
A gauge anywhere in between that doesn't move indicates an open circuit (blown fuse; corroded terminal) on the power (battery) side of the gauge OR a bad instrument cluster ground at C251 pin 9 (both of which would affect MORE of the cluster than strictly the fuel level gauge). To test it, ground the Y/Wh wire as close to the instrument cluster as possible, and turn the key to RUN. If the gauge instantly moves toward E, the gauge & its power/ground are good, and the fault is PAST where you grounded the Y/Wh wire. If not, the fault is BEFORE that point, in the gauge, cluster, or power/ground wiring.
The terminals of C251 (& C250) are known to corrode & lose contact (open), which would cause the gauge to read high or peg past Full. Polish both the connector pins AND the film circuit pads with brown paper or a pink eraser.
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The larger/older version of C441(WPT454) was used until '93.
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A medium-sized connector was used from '93-95.
The level sender can usually be disassembled & repaired by bending the wiper arm inside the plastic housing to apply slightly more force. See the other photos in this album.
For more info, see these albums' captions:
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-Bronco ONLY-
See also:
MotorCraft 2016 Wiring Pigtail Guide 
![fuellevelwiring.jpg Fuel Level Sender & Gauge Wiring for '92-96 Broncos ('87-91 Bronco similar)
IF THE IMAGE IS TOO SMALL, click it.
For '87-96 F-series w/dual tanks, see:
[url=https://www.supermotors.net/registry/media/1126824][img]https://www.supermotors.net/getfile/1126824/thumbnail/fueltanksfgas.jpg[/img][/url]
ERROR: C251 pin 5 should read "Fuel ResEt Indicator Input", but that circuit is not present on most trucks, and not used on any. There may be other errors or variations due to model year changes & optional equipment.
Sender Range: 160 (full) - 16 (empty) Ohms
A gauge that pegs past full indicates an open circuit on the Y/W wire (broken wire; unplugged connector; corroded terminal; varnished sender; F-series - selector switch or connector faults).
A gauge that pegs past empty indicates a short to ground on the Y/W wire (pinched to the frame, body, or dash supports), a fault in the gauge or its power or ground from the film circuit, OR a sunken float.
A gauge anywhere in between that doesn't move indicates an open circuit (blown fuse; corroded terminal) on the power (battery) side of the gauge OR a bad instrument cluster ground at C251 pin 9 (both of which would affect MORE of the cluster than strictly the fuel level gauge). To test it, ground the Y/Wh wire as close to the instrument cluster as possible, and turn the key to RUN. If the gauge instantly moves toward E, the gauge & its power/ground are good, and the fault is PAST where you grounded the Y/Wh wire. If not, the fault is BEFORE that point, in the gauge, cluster, or power/ground wiring.
The terminals of C251 (& C250) are known to corrode & lose contact (open), which would cause the gauge to read high or peg past Full. Polish both the connector pins AND the film circuit pads with brown paper or a pink eraser.
[url=http://www.supermotors.net/registry/media/774679][img]http://www.supermotors.net/getfile/774679/thumbnail/clusterparts.jpg[/img][/url] . [url=http://www.supermotors.net/registry/media/695679][img]http://www.supermotors.net/getfile/695679/thumbnail/c251.jpg[/img][/url]
The larger/older version of C441(WPT454) was used until '93.
[url=http://www.supermotors.net/registry/media/766463][img]http://www.supermotors.net/getfile/766463/thumbnail/fuelpumpconnectors.jpg[/img][/url] . [url=https://www.supermotors.net/registry/media/1164369][img]https://www.supermotors.net/getfile/1164369/thumbnail/pumpconnectors8797.jpg[/img][/url] . [url=https://www.supermotors.net/registry/media/744424][img]https://www.supermotors.net/getfile/744424/thumbnail/fpconnectors.jpg[/img][/url]
A medium-sized connector was used from '93-95.
The level sender can usually be disassembled & repaired by bending the wiper arm inside the plastic housing to apply slightly more force. See the other photos in this album.
For more info, see these albums' captions:
[url=http://www.supermotors.net/registry/2742/84974-4][img]http://www.supermotors.net/getfile/1067160/thumbnail/intro01.jpg[/img][/url] . [url=https://www.supermotors.net/registry/media/1164171_1][img]https://www.supermotors.net/getfile/1164171/thumbnail/notquite.jpg[/img][/url] . [url=http://www.supermotors.net/registry/2742/34307-4][img]http://www.supermotors.net/getfile/434941/thumbnail/lfl_on.jpg[/img][/url] . [url=http://www.supermotors.net/registry/2742/33276-4][img]http://www.supermotors.net/getfile/766383/thumbnail/03check.jpg[/img][/url]-Bronco ONLY-[url=http://www.supermotors.net/registry/media/1024360][img]http://www.supermotors.net/getfile/1024360/thumbnail/49fuelcal.jpg[/img][/url]
See also:
[url=https://www.fordparts.com/FileUploads/CMSFiles/18376%20Pigtail%20Book%202016.pdf]MotorCraft 2016 Wiring Pigtail Guide[/url]](https://www.supermotors.net/getfile/744437/fullsize/fuellevelwiring.jpg)