FuelLevelWiring.JPG
22400 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...
FuelLevel01.JPG
4960 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...
FuelLevel03.JPG
3210 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...
FuelLevel04.JPG
3003 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 ...
FuelLevel05.JPG
2772 hits | 76.62 KB | Posted: 6/24/11

Flip the sender for access to its clips.
FuelLevel06.JPG
2888 hits | 77.21 KB | Posted: 6/24/11

Cut off the melted peg(s).
FuelLevel07.JPG
2552 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...
FuelLevel08.JPG
2622 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...
FuelLevel09.JPG
2573 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 ...
FuelLevel10.JPG
2921 hits | 70.41 KB | Posted: 6/24/11

This is the board before cleaning...
FuelLevel11.JPG
2766 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 ...
FuelLevel12.JPG
2506 hits | 88.71 KB | Posted: 6/24/11

Polish the mating surfaces between the hard line plate (still screwed to the FDM) and the sender bac...
FuelLevel13.JPG
2459 hits | 82.47 KB | Posted: 6/24/11

Polish the area around the float arm pivot hole where the brass wipers will touch.
FuelLevel14.JPG
2594 hits | 78.59 KB | Posted: 6/24/11

After reassembling the rheostat board, sender housing, wiper arm, & backing plate, press the arm bac...
FuelLevel15.JPG
2802 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 ...
Floats.jpg
452 hits | 32.54 KB | Posted: 3/13/21

Fuel Floats
IF THE IMAGE IS TOO SMALL, click it.

[url=https://www.supermotors.net/registry/media/76...
LevelSenderRebuild.jpg
537 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...

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