Fuel Tank Sending Unit Issues..HELP!

[teddyd49]

I finally got around to taking out my old sending unit that was no longer working to see what might be the problem. Per the great tips provided on this forum, I disassembled the unit and found that sludge/grime build-up had indeed rendered this unit non functional.

I carefully removed all sludge and cleaned the unit thoroughly.

I inadvertantly snapped one of the guide wires/electrical wire connections (brass wire) that runs the length of the unit top to bottom. I had a friend reattach/resolder this wire back to its original connection at top of unit. It was now locked and ready to install. It almost looked brand new.

The one issue I had before reinstalling this unit was the fact that rust and pitting had settled onto the chrome shaft at both the top and bottom of the shaft that might impair the working of the float (ability to freely move up and down with fuel levels). I did a cursory job of sanding these areas on the shaft but not a complete job. By the time I had noticed this, I had already reattached/affixed the electrical connections on the unit; and this left little space to work in to do more sanding/polishing without breaking these wires once again.

To my dismay, the sending unit works sporadically now...not like new as advertised. It sometimes registers a current to the fuel gauge and it sometimes does not. And if it registers a fuel level at all, it only moves up to the 1/4 tank level even though the fuel tank is full.

Does anybody have any ideas on what I might have done wrong, or what might be causing this all to happen? Before I took unit out, it was permanently recording a FULL TANK (I suppose the float was stuck at this level permanently due to sludge build-up).

While this turned out to be a much easier job than I thought it would be, I've ended up with BUPKUS on this front.