Damaged Fuel Sender pictures
#1
10-14-2009, 08:57 PM
Damaged Fuel Sender pictures
This issue is on a 1999 dodge 3500 and many other Ram models. I would like to pass this info on to you all. During a recent Air Dog pump upgrade i found my Fuel sender pretty worn out in the area of the metal holder to plastic housing. The screws appeared to be wearing badly. I just drilled new holes being sure they didn't interfere with the stock tubes inside the housing for Fuel pressure and retun.
The plastic base of the housing sits on the bottom of the tank but I found my sender float was not bottomed on the reostat in this position ( resistance was around 112.0 OHMs) so when the tank is empty it still shows that you have a little fuel (this is no big news to most dodge guys).
You could bend the arm of the float so that the lowest level is truly the bottom of the tank (approx 125.7 Ohms) or what I did is mesured the depth to the bottom of my tank and set the slider on the metal support to plastic housing at my distance by installing washers and four new holes away from the wear spots.
The other problem with the sender is that the reostat itself has nothing to hold it together but a plastic tab that rides under another plastic retaining groove. As this wears it lets the tension off of the contacts (2 Each) and gives erratic or no fuel readings.
The sender can be taken appart and some people have repaired them as a new sender is 200 to 400 Dollars as an assembly. Below are some pictures of how we fixed mine with a 4-40 thread die and a 4-40 lock nut with washer (small MS aircraft nut). Just drive out the shaft pin out the back of the reostat and the plastic arm comes off clean it all up and check contacts for good spring tension. Trim back the plastic **** on the end of the plastic arm till its even with the larger portion of the Boss arm. hold the shaft and thread it with the die slide it all back together and check resistance.
Hope this helps if you need one of these small 4-40 nuts let me know!!
The plastic base of the housing sits on the bottom of the tank but I found my sender float was not bottomed on the reostat in this position ( resistance was around 112.0 OHMs) so when the tank is empty it still shows that you have a little fuel (this is no big news to most dodge guys).
You could bend the arm of the float so that the lowest level is truly the bottom of the tank (approx 125.7 Ohms) or what I did is mesured the depth to the bottom of my tank and set the slider on the metal support to plastic housing at my distance by installing washers and four new holes away from the wear spots.
The other problem with the sender is that the reostat itself has nothing to hold it together but a plastic tab that rides under another plastic retaining groove. As this wears it lets the tension off of the contacts (2 Each) and gives erratic or no fuel readings.
The sender can be taken appart and some people have repaired them as a new sender is 200 to 400 Dollars as an assembly. Below are some pictures of how we fixed mine with a 4-40 thread die and a 4-40 lock nut with washer (small MS aircraft nut). Just drive out the shaft pin out the back of the reostat and the plastic arm comes off clean it all up and check contacts for good spring tension. Trim back the plastic **** on the end of the plastic arm till its even with the larger portion of the Boss arm. hold the shaft and thread it with the die slide it all back together and check resistance.
Hope this helps if you need one of these small 4-40 nuts let me know!!
The following users liked this post:
Queeg (10-25-2009)
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