Steve83 > 1983 Ford Bronco > open folder Fuel Level Sender Repair

Fuel Level Sender & Gauge Wiring for '92-96 Broncos ('87-91 Bronco similar)IF THE IMAGE IS TOO SMAL...
FuelLevelWiring.JPG
23080 hits | 78.84 KB | Posted: 7/19/09
Fuel Level Sender & Gauge Wiring for '92-96 Broncos ('87-91 Bronco similar)
IF THE IMAGE IS TOO SMAL...
As much of an improvement as the FDM system was over the previous EFI pump system, it's still subjec...
FuelLevel01.JPG
5148 hits | 54.03 KB | Posted: 6/24/11
As much of an improvement as the FDM system was over the previous EFI pump system, it's still subjec...
Pry the float arm out of the sender clip, being careful not to break the plastic. Prying between th...
FuelLevel03.JPG
3381 hits | 74.2 KB | Posted: 6/24/11
Pry the float arm out of the sender clip, being careful not to break the plastic. Prying between th...
Remove these two 1/4" screws and the one below the sender (LEFT in the photo), leaving the one ...
FuelLevel04.JPG
3151 hits | 77.87 KB | Posted: 6/24/11
Remove these two 1/4" screws and the one below the sender (LEFT in the photo), leaving the one ...
Flip the sender for access to its clips.
FuelLevel05.JPG
2918 hits | 76.62 KB | Posted: 6/24/11
Flip the sender for access to its clips.
Cut off the melted peg(s).
FuelLevel06.JPG
3029 hits | 77.21 KB | Posted: 6/24/11
Cut off the melted peg(s).
Release the catch and slide the plastic housing off the metal plate. To make reassembly easier, t...
FuelLevel07.JPG
2697 hits | 77.62 KB | Posted: 6/24/11
Release the catch and slide the plastic housing off the metal plate.

To make reassembly easier, t...
The wiper arm is loose inside the sender housing, without the float arm to hold it. The rheostat bo...
FuelLevel08.JPG
2789 hits | 77.77 KB | Posted: 6/24/11
The wiper arm is loose inside the sender housing, without the float arm to hold it. The rheostat bo...
To clean the board, I use #000 steel wool; for the brass wiper contacts, 400gr. emery paper. After ...
FuelLevel09.JPG
2711 hits | 74.57 KB | Posted: 6/24/11
To clean the board, I use #000 steel wool; for the brass wiper contacts, 400gr. emery paper. After ...
This is the board before cleaning...
FuelLevel10.JPG
3074 hits | 70.41 KB | Posted: 6/24/11
This is the board before cleaning...
...this is after. DO NOT CLEAN the green areas since they provide the necessary resistance, and any ...
FuelLevel11.JPG
2907 hits | 71.96 KB | Posted: 6/24/11
...this is after. DO NOT CLEAN the green areas since they provide the necessary resistance, and any ...
Polish the mating surfaces between the hard tubes' plate (still screwed to the FDM) and the sender b...
FuelLevel12.JPG
2659 hits | 88.71 KB | Posted: 6/24/11
Polish the mating surfaces between the hard tubes' plate (still screwed to the FDM) and the sender b...
Polish the area around the float arm pivot hole where the brass wipers will touch.
FuelLevel13.JPG
2587 hits | 82.47 KB | Posted: 6/24/11
Polish the area around the float arm pivot hole where the brass wipers will touch.
After reassembling the rheostat board, sender housing, wiper arm, & backing plate, press the arm bac...
FuelLevel14.JPG
2743 hits | 78.59 KB | Posted: 6/24/11
After reassembling the rheostat board, sender housing, wiper arm, & backing plate, press the arm bac...
Finally, check the sender's output over the full range, making sure it produces a smooth continuous ...
FuelLevel15.JPG
2984 hits | 93.35 KB | Posted: 6/24/11
Finally, check the sender's output over the full range, making sure it produces a smooth continuous ...
Fuel FloatsIF THE IMAGE IS TOO SMALL, click it.Foam cylinder [url=https://www.amazon.com/dp/B00VW...
Floats.jpg
676 hits | 32.54 KB | Posted: 3/13/21
Fuel Floats
IF THE IMAGE IS TOO SMALL, click it.

Foam cylinder [url=https://www.amazon.com/dp/B00VW...
Since genuine level senders aren't available, imported copies will have to do. Fortunately, it's che...
LevelSenderRebuild.jpg
890 hits | 58.18 KB | Posted: 2/17/22
Since genuine level senders aren't available, imported copies will have to do. Fortunately, it's che...
Level Sender Testing IF THE IMAGE IS TOO SMALL, click it. Before re-installing a sender in the t...
GasGTest.jpg
125 hits | 79.67 KB | Posted: 7/13/24
Level Sender Testing
IF THE IMAGE IS TOO SMALL, click it.

Before re-installing a sender in the t...