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EFV-8 Club Forum / General Ford Discussion / Fuel Sender continued... leaking bad

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Discussion Topic: Fuel Sender continued... leaking bad

wlobb

07-30-2025 @ 5:49 AM

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Member
Posts: 58
Joined: Jul 2024

Hi guys!

I posted earlier about my fuel sender not working and got some good advice and things to try. I took it apart Saturday and found (see pic) the float was missing. What I also found was the guy who had it before tried to make a 6-hole sender work on a repro 5-hole tank by drilling out the top of the sender. He got it close, but not close enough. This also explains the mystery goop all over the screws.

Here is the problem: I don't think the guy had the rights screws, it looks like he tried to use #10-32 screws, not the course thread #10-24, so the holes were a bit stripped.

I tapped them with a #10-24 and four of the five tightened up nice, but one is stripped. My plan is to tap the holes with a M6 metric tap, this looks to be a brand-new tank. I'd like to keep it, if I can make this work. M6 is about a millimeter (a bit bigger than a 1/16th.) Does anyone see a problem with tapping all five holes with the M6?

I can write a note in magic marker on the tank, besides this car is already willed to my grandboy, so it won't be a dirty trick to the next guy. I ordered a five hole from Shoebox Central, should be here this week.

Thanks,
Bill

This message was edited by wlobb on 7-30-25 @ 6:20 AM

juergen

07-31-2025 @ 5:58 AM

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Joined: Jan 2010

Well for one, the sender is a repro sender. Is it compatible with your gauge? I would check it out. Hook it up, including the ground and see what the gauge reads as you move the arm from empty to full.

Next how are you keeping the little filings from the threader from entering the tank? These could screw up your fuel pump, carburetor and engine. Can you capture them on your tap or getting something sticky into the hole to catch any filings?

wlobb

07-31-2025 @ 11:00 AM

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Posts: 58
Joined: Jul 2024

Hi, the gauge doesn't work at all, the float is gone. Actually, that's not true. When I put the sender back i had moved the arm where the float would have been and that's changed where the gauge read, so that's a good thing. I know my wiring is good.

This was definitely cob-job, trying to make the 6-hole unit work on a five-hole tank. The screw holes don't go all the way through, so that is lucky, it's like the top of the tank is steel rolled over onto itself, so I can keep the metal from big hole pretty easily. I'm wondering now, I havent pulled it apart yet, I m waiting on my 5-hole sender from Shoebox Central, and its been about 100 degrees here this week, if the screw might be what's stripped and not the threads into the tank. If I get lucky there this may not even require a retap.

Thanks again.

Bill

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