Fuel Level Sender Repair

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… Owner 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… Owner 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… Owner 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… Owner Flip the sender for access to its clips. Owner Cut off the melted peg(s). Owner 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… Owner 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… Owner 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… Owner This is the board before cleaning... Owner ...this is after. DO NOT CLEAN the green areas since they provide the necessary resistance, and any cleaning can permanently change that. N… Owner 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… Owner Polish the area around the float arm pivot hole where the brass wipers will touch. Owner After reassembling the rheostat board, sender housing, wiper arm, & backing plate, press the arm back into the wiper clip. It may be necess… Owner 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… Owner 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:… Owner Since genuine level senders aren't available, imported copies will have to do. Fortunately, it's cheap & easy to swap virtually any '87-04… Owner 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… Owner