Fuel Sending Unit

[jss06c6]

Found one and ordered from Parts Train ($378 shipped).

Refurbished the Sending Unit.

1. Carefully open the two tabs on the winding side of the potentiometer
Wiper Bow.jpg
2. Slowly lift off the winding housing by lifting away from the two tabs that have been bent open and ease off of the wiper shaft
3. With WD-40 and cue-tip or clean shop towel (blue paper), very carefully wipe the windings clean..
Sending Unit Winding.jpg
4. Then, using a new cue-tip or shop towel (blue paper), clean the wiper contact (brass). Mine was black with 27 years of junk.
Sending Unit Wiper.jpg
5. Gently flex the contact tip spring open so that you get a little more spring pressure on the wiper/winding contact (see photo under step 1)
6. Reassemble by slipping the housing back under the tab that was not opened and over the wiper shaft. Then bend the two tabs you opened back down to secure the unit.
Sending Unit Tabs Closed.jpg
7. Recheck full sweep on the potentiometer, making sure it reads steady at any point (no matter how much you move the float shaft side to side) and that it smoothly sweeps from 1.4 ohms (tank empty on mine) to 92 ohms (tank full on mine).
Sending Unit Test Connections.jpg

Note: I could get the sending unit to be erratic before opening and cleaning the potentiometer by moving the float shaft side to side, especially at the tank full position. Further, I could duplicate the lack of response in the top range of the sending unit. There was enough junk on the wiper contact and the windings to cause it to be erratic. After this rebuild, the unit is rock steady, no matter what the position of the float arm!