If one (or both) of the wires in your sender have broken, here's what you need to know to fix them.

One of the wires is nichrome resistance wire or something similar. In the "Disassembled" picture (above), it's the upper wire, the one closest to you in the picture (both wires are invisible in the picture -- too small). The lower wire, next to the fabric on which the sender is lying, is ordinary wire.

The two wires cannot be switched. The "ordinary" wire is part of the low-fuel light circuit and needs to be low resistance or the light won't work. The resistance wire makes the fuel gauge work.

The resistance wire measures 7.5 Ohms per inch (3 Ohms per centimeter). It is 0.0015 inch (0.04 mm) in diameter or 46 gauge. You may be able to buy nichrome resistance wire at a good electronics store.

The other wire is about 0.004 inch (0.10 mm) in diameter or 38 gauge. Any fine-gauge wire will work. One forum member took one strand from a stranded wire and made his sender work.

Jeremy

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