FuelLevelWiring.JPG
23080 hits | 78.84 KB | Posted: 7/19/09
Fuel Level Sender & Gauge Wiring for '92-96 Broncos ('87-91 Bronco similar)
IF THE IMAGE IS TOO SMAL...

FuelLevel01.JPG
5148 hits | 54.03 KB | Posted: 6/24/11
As much of an improvement as the FDM system was over the previous EFI pump system, it's still subjec...

FuelLevel03.JPG
3381 hits | 74.2 KB | Posted: 6/24/11
Pry the float arm out of the sender clip, being careful not to break the plastic. Prying between th...

FuelLevel04.JPG
3151 hits | 77.87 KB | Posted: 6/24/11
Remove these two 1/4" screws and the one below the sender (LEFT in the photo), leaving the one ...

FuelLevel05.JPG
2918 hits | 76.62 KB | Posted: 6/24/11
Flip the sender for access to its clips.

FuelLevel06.JPG
3029 hits | 77.21 KB | Posted: 6/24/11
Cut off the melted peg(s).

FuelLevel07.JPG
2697 hits | 77.62 KB | Posted: 6/24/11
Release the catch and slide the plastic housing off the metal plate.

To make reassembly easier, t...

FuelLevel08.JPG
2789 hits | 77.77 KB | Posted: 6/24/11
The wiper arm is loose inside the sender housing, without the float arm to hold it. The rheostat bo...

FuelLevel09.JPG
2711 hits | 74.57 KB | Posted: 6/24/11
To clean the board, I use #000 steel wool; for the brass wiper contacts, 400gr. emery paper. After ...

FuelLevel10.JPG
3074 hits | 70.41 KB | Posted: 6/24/11
This is the board before cleaning...

FuelLevel11.JPG
2907 hits | 71.96 KB | Posted: 6/24/11
...this is after. DO NOT CLEAN the green areas since they provide the necessary resistance, and any ...

FuelLevel12.JPG
2659 hits | 88.71 KB | Posted: 6/24/11
Polish the mating surfaces between the hard tubes' plate (still screwed to the FDM) and the sender b...

FuelLevel13.JPG
2587 hits | 82.47 KB | Posted: 6/24/11
Polish the area around the float arm pivot hole where the brass wipers will touch.

FuelLevel14.JPG
2743 hits | 78.59 KB | Posted: 6/24/11
After reassembling the rheostat board, sender housing, wiper arm, & backing plate, press the arm bac...

FuelLevel15.JPG
2984 hits | 93.35 KB | Posted: 6/24/11
Finally, check the sender's output over the full range, making sure it produces a smooth continuous ...

Floats.jpg
676 hits | 32.54 KB | Posted: 3/13/21
Fuel Floats
IF THE IMAGE IS TOO SMALL, click it.

[url=https://www.supermotors.net/registry/media/76...

LevelSenderRebuild.jpg
890 hits | 58.18 KB | Posted: 2/17/22
Since genuine level senders aren't available, imported copies will have to do. Fortunately, it's che...

GasGTest.jpg
125 hits | 79.67 KB | Posted: 7/13/24
Level Sender Testing
IF THE IMAGE IS TOO SMALL, click it.

Before re-installing a sender in the t...