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#1
05-11-2009, 08:26 AM
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Fuel Tank Sending Unit Issues..HELP!
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. 
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#2
05-11-2009, 08:36 AM
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Year and model?
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#4
05-11-2009, 09:31 AM
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If you want another one to try, let me know in a PM or email.
__________________
daw_two Germantown, TN Links: Sold last car --- 05/2012 1984 300D Light Ivory, Red interior Cluster Needles Paint New Old Stock (NOS) parts Past: 3/2008 1986 300SDL "Coda" 04/2010 1965 190D(c) "Ben" & many more
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#8
05-11-2009, 12:07 PM
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Get a new/used unit.
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#10
05-11-2009, 12:19 PM
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Different models have different tricks.
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#11
05-11-2009, 01:12 PM
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It appears that the float gets hung up along the shaft hence the erratic gage. Depending on your patience level, you could disassemble the unit again and clean the shaft thoroughly.
Sometime back, I found one of the copper wires broken on my SU. I took a hair of copper wire from a strand and soldered it to join the broken wire. It works fine now. B4, it never registered correctly.
__________________
the sooner you start... the sooner you'll get done  If it ain't broke, don't fix it.. Its always simpler to tell the truth... 2007 Honda Accord EX 2007 Honda Accord SE V6 96 C220 97 Explorer - Found Another Home 2000 Honda Accord V6 - Found Another Home 85 300D - Found Another Home 84 300D - Found Another Home 80 300TD - Found Another Home Previous cars: 96 Caravan 87 Camry 84 Cressida 82 Vanagon 80 Fiesta 78 Nova Ford Cortina Opel Kadet 68 Kombi Contessa
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#12
05-11-2009, 03:56 PM
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I am going to have to disassemble the unit once more after I take it out of the tank again. What I am hoping someone will give me is a check list (a la Toby) so that I can cover all bases before reinserting fuel sending unit into tank once again. I believe all contacts are good but will use ohmmeter to confirm.
Is there anything electrical OUTSIDE of the sending unit that needs to be checked to insure the juice is reaching the fuel gauge??????? I am hell bent to get this thing fixed if at all possible....thanks one and all.
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#13
05-11-2009, 04:17 PM
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try this.....
Once you think you have it repaired; hook it up to the wiring harness with it OUT of the tank. Turn the key on. Raise and lower the float.....slowly and see if it registers correctly on the gauge.
Just a thought I had......while in the "hurry up and wait" mode at work.
__________________
daw_two Germantown, TN Links: Sold last car --- 05/2012 1984 300D Light Ivory, Red interior Cluster Needles Paint New Old Stock (NOS) parts Past: 3/2008 1986 300SDL "Coda" 04/2010 1965 190D(c) "Ben" & many more
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#15
05-12-2009, 09:20 AM
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two choices- repair (again, maybe) or replace. since it is fairly easy to get at, I'd try to shine up the rod w/ some fine emery cloth- like what you get in the plumbing section @ yer big box. it is usually a 1.5 inch wide roll, like masking tape, but sand paper.
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