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EFV-8 Club Forum / General Ford Discussion / Fuel Sender Problem on '46 Coupe

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Discussion Topic: Fuel Sender Problem on '46 Coupe

51woodie

07-30-2019 @ 1:20 PM

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It all started when I got my dash gauges working, and found the fuel gauge to be inaccurate. A full tank was showing 3/4 full, and empty still had about 5 gallons in the tank. I tested the volts at the tank, "shorted" the gauge lead at the tank, and the gauge reads full range. I pulled the sender unit, and what I found was not pretty. The PO used some sort of rubber gasket, which had partially dissolved with pieces falling into the tank. Fished those out. As well, I found the sender must be aftermarket because of the plastic float. That is the next issue, as the float is 1/2 full of some type of fluid. I thought it may be leaking and gas had got in. I squeezed the float, and cannot find a leak. I may be a silly question, but are they made this way? The other thing is that the float arm is too long in my opinion, which means the float will hit the top or bottom of the tank, but will only travel about 3/4 of the range between the top and bottom stops on the sender. Ideally I would like to have a NOS sender if one was available at a reasonable price, but:

Any suggestions on "adjusting" the float arm to get full range of travel?
Is the float prefilled? If not, can I drill drain and reseal?
Is a cork gasket appropriate for mounting the sender?

I also posted this on the Ford Barn

51woodie

07-30-2019 @ 1:27 PM

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I forgot to ask the correct orientation of the float arm. I assume it would be side to side?

07-30-2019 @ 3:13 PM

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There should be no fluid in the float - get/buy a new float. Use a cork gasket and fuel proof sealer. No problem with sender & arm orientation as the sender can only be installed one way - just line up the holes in the sender with the holes in the tank. When the tank is empty, the float should rest just above the bottom of the tank while engaging the bottom stop of the sender - you don't want the float resting/touching the bottom of the tank.. When the tank is full, the upper stop on the sending unit should be engaged by the arm. From the picture you posted, it looks as though the arm on the sender is a little too long for the tank application....

37RAGTOPMAN

07-30-2019 @ 3:13 PM

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I think the float is no good, never saw fluid in one, it probably has a very small crack in it
I would drain it and see what is in it,
you can look for a brass float on E-BAY,
Just make sure it is the same size, or close to it,
the way you have it mocked up is the way to go,
use long jumper wire to test the sender and gauge,
my 2 cents 37Ragtopman

carcrazy

07-30-2019 @ 9:33 PM

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You can buy a brand new gas tank sending unit from MAC's Auto Parts. It includes the float and a neoprene gasket. The part number is 99A-9275 and the price is $34.95. It has a fully adjustable length to accommodate any type vehicle or gas tank with original Ford dash gauges, it has 6 mounting holes and detailed mounting instructions are included.

51woodie

07-31-2019 @ 3:47 AM

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Thanks for the responses. carcrazy I wonder if the gasket in the picture was neoprene? I looked at Mac's and DC and they have several options for floats and senders.

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