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  #1  
Old 11-26-2009, 07:03 AM
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fuel gauge sending unit broken wire!!!

86 300 SDL
driven daily by kid who came home Tuesday said fuel gauge not working.
checked fuses everything good.
pulled sending unit and took it apart. One of the very small diameter wires had broken and wrapped around float.
In process of unwrapping the wire broke again
where to get the wire??? and can it be soldered??????? what type of wire???

ideas?????
al mitchel
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  #2  
Old 11-26-2009, 10:19 AM
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Quote:
Originally Posted by grubbyfrozen View Post
where to get the wire??? and can it be soldered??????? what type of wire???
Don't despair - it can be repaired, see the bottom of this DYI article:
http://www.peachparts.com/Wikka/W124FuelSender

Good luck -
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1987 Mercedes 300SDL; SOLD
1985 Mercedes 300D; SOLD
2006 Honda Pilot - wife's ride; 122K;
1995 Toyota Land Cruiser - 3X locked; 182K
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  #3  
Old 11-26-2009, 01:23 PM
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That is what I needed to know. Thanks a bunch.

Where to buy??? radio shack??? this the stuff????
http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&item=310090965642&rvr_id=&crlp=1_263602_263622&UA=WXF%3F&GUID=4d8482011220a03663e4f644ffe03623&itemid=310090965642&ff4=263602_263622
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  #4  
Old 11-26-2009, 01:30 PM
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Wait just read to the end of suggested page.
Again thanks a lot. Now back to the turkey and ham.
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  #5  
Old 11-26-2009, 01:36 PM
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I have soldered ONE end of one of those those wires once and it worked. You might be able to do both. What do you have to lose.
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1985 Euro 300TD 5 spd 220K
1985 Euro 240D 5 spd 130K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

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  #6  
Old 11-26-2009, 02:36 PM
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Sender

I've soldered both and replaced one w/o too much of a problem...my only challenge was I didn't pay enough attention to the "wipers" that are positioned at the edge of the float where the wire passes through. Look at the side that's intact before you fully disassemble the sender. If you don't get them positioned correctly (and they're tiny little things) they will only contact the wire intermittently and your guage will jump laround like a pogo stick.
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  #7  
Old 11-29-2009, 07:51 AM
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Got the wires soldered and I did see the little "wipers". Gauge is working but does want to jump around some. May have to pull the sending unit again to check the contact points.
Called several electronic stores and no one could help with the wire. Where can you buy new nichromium wire??
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  #8  
Old 11-29-2009, 08:51 AM
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Location: Kandy, Srilanka.
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Quote:
Originally Posted by grubbyfrozen View Post
86 300 SDL
driven daily by kid who came home Tuesday said fuel gauge not working.
checked fuses everything good.
pulled sending unit and took it apart. One of the very small diameter wires had broken and wrapped around float.
In process of unwrapping the wire broke again
where to get the wire??? and can it be soldered??????? what type of wire???

ideas?????
al mitchel
Hello,
They are nichrome wires go to your local shop that sells electronics ect.. radio shack may be and show them the wire and get some, dont try to strech the old wire and solder it on, it has to be the same lenth, if you strech it to get enough to solder it you will find that the gauge will not start from the begining or stop at the end, resulting in a reading that is not very accurate becouse the nichrome wire will be even a few milimeters short resulting in a big change in resistance so get some new wire and wrap it of the original lenth (not too tight not too loose) and solder it on the two ends, look how the old wire goes so you wont foget how to put in the new wire
good luck Jeremy Brett
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  #9  
Old 11-30-2009, 11:47 AM
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Now that we have a week off from deer hunting, Indiana. I plan to visit
radio shack and see what they have. Tried calling but the person I talked to
didn't seem to have a clue.
the solder job still seems to be working.
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  #10  
Old 11-30-2009, 02:55 PM
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Quote:
Originally Posted by grubbyfrozen View Post
Now that we have a week off from deer hunting, Indiana. I plan to visit
radio shack and see what they have. Tried calling but the person I talked to
didn't seem to have a clue.
the solder job still seems to be working.
break off a pice of that wire and take it to radio shack and have them check the gauge so you can get about half a meter or so in case make sure the wire goes in between the the contacts of the floater on both sides, and you cant quite solder nichrome wire, it just does'nt stick so chances are if you use the same old wire soldered its going to come off
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  #11  
Old 11-30-2009, 03:51 PM
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Quote:
Originally Posted by pixelsblack009 View Post
break off a pice of that wire and take it to radio shack and have them check the gauge so you can get about half a meter or so in case make sure the wire goes in between the the contacts of the floater on both sides, and you cant quite solder nichrome wire, it just does'nt stick so chances are if you use the same old wire soldered its going to come off
Mines still holding, its been three years at least and Im not a very practiced solderer
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1985 Euro 300TD 5 spd 220K
1985 Euro 240D 5 spd 130K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"
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  #12  
Old 11-30-2009, 05:37 PM
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Quote:
Originally Posted by Stevo View Post
Mines still holding, its been three years at least and Im not a very practiced solderer
Hmm,
yeah but not if its broken off from the end and if you are trying to join both ends and solder it, I know it would sort of stick if you are soldering the contacts on which the nichrome wire wraps around at the two ends at the bottom because those contacts on which the wire wraps around at the two ends itself are made out of copper, just try putting some solder on a pice of nichrome wire and you will see it doesn't stick like it does on a copper wire, but that's what happened to me may be It was that my 50W soldering iron was not hot enough to solder nichrome, I was going to try it with my 80W but it broke on me before I could try, so could you really solder nichrome then ????
Jeremy Brett
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  #13  
Old 11-30-2009, 05:38 PM
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Location: Rochester, NY
Posts: 180
Jumpin' Guage after repair

Sme happened to me...THATs how I found out I'd missed threading the wires through the wipers properly...always fun to take it apart twice!
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  #14  
Old 11-30-2009, 05:50 PM
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Location: Kandy, Srilanka.
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Sorry, sorry, I could'nt find nichrome of that gauge where I live namely srilanka, so I you know you get these heating elements you get in soldering irons, so that once you burn your element and your soldering iron wont work anymore you can buy a new element, well I took apart a 30W element and used the wire from the nichrome coil in it, its exactly the same gauge and wire they use on the elements that is used on the floater, cost me 30 Rupees and you get more than 6 meters in it thats definitely worth the money I paid for it
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  #15  
Old 11-30-2009, 08:15 PM
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Quote:
Originally Posted by pixelsblack009 View Post
Hmm,
yeah but not if its broken off from the end and if you are trying to join both ends and solder it, I know it would sort of stick if you are soldering the contacts on which the nichrome wire wraps around at the two ends at the bottom because those contacts on which the wire wraps around at the two ends itself are made out of copper, just try putting some solder on a pice of nichrome wire and you will see it doesn't stick like it does on a copper wire, but that's what happened to me may be It was that my 50W soldering iron was not hot enough to solder nichrome, I was going to try it with my 80W but it broke on me before I could try, so could you really solder nichrome then ????
Jeremy Brett
Oh yah, If it had to be joined in the middle I would have broken out the spare unit and tossed it in the "broken' pile.
It took two of us to do it as it was
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1985 Euro 300TD 5 spd 220K
1985 Euro 240D 5 spd 130K
1979 240D 5 spd, 40K on engine rebuild
1994 Dodge/Cummins, 5 spd, 121K
1964 Allice Chalmers D15 tractor
2014 Kubota L3800 tractor
1964 VW bug

"Lifes too short to drive a boring car"
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