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Fuel Level Sender Repair

From 1983 Ford Bronco “That dirty old truck” — documented by Steve83.

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1983 Ford Bronco - 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… 1983 Ford Bronco - As much of an improvement as the FDM system was over the previous EFI pump system, it's still subject to failures, mostly related to fuel v… 1983 Ford Bronco - Pry the float arm out of the sender clip, being careful not to break the plastic. Prying between the clip & the pivot hole is the most-effe… 1983 Ford Bronco - Remove these two 1/4" screws and the one below the sender (LEFT in the photo), leaving the one that holds the FDM to the hard lines ab… 1983 Ford Bronco - Flip the sender for access to its clips. 1983 Ford Bronco - Cut off the melted peg(s). 1983 Ford Bronco - Release the catch and slide the plastic housing off the metal plate. To make reassembly easier, trim the peg that was cut off so it does NO… 1983 Ford Bronco - The wiper arm is loose inside the sender housing, without the float arm to hold it. The rheostat board snaps into the housing. It's easy to… 1983 Ford Bronco - To clean the board, I use #000 steel wool; for the brass wiper contacts, 400gr. emery paper. After polishing the brass, gently bend it so i… 1983 Ford Bronco - This is the board before cleaning... 1983 Ford Bronco - ...this is after. DO NOT CLEAN the green areas since they provide the necessary resistance, and any cleaning can permanently change that. N… 1983 Ford Bronco - Polish the mating surfaces between the hard tubes' plate (still screwed to the FDM) and the sender backing plate so the sender has a good g… 1983 Ford Bronco - Polish the area around the float arm pivot hole where the brass wipers will touch. 1983 Ford Bronco - After reassembling the rheostat board, sender housing, wiper arm, & backing plate, press the arm back into the wiper clip. It may be necess… 1983 Ford Bronco - Finally, check the sender's output over the full range, making sure it produces a smooth continuous signal from ~16~160 Ohms. If not, repla… 1983 Ford Bronco - Fuel Floats IF THE IMAGE IS TOO SMALL, click it. Foam cylinder (genuine Krueger) or (cheap copy) '87-04 sender w/cylinder float [url=https:… 1983 Ford Bronco - Since genuine level senders aren't available, imported copies will have to do. Fortunately, it's cheap & easy to swap virtually any '87-04… 1983 Ford Bronco - Level Sender Testing IF THE IMAGE IS TOO SMALL, click it. Before re-installing a sender in the tank, test gauge response in at least 3 posi…