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Hits: 23080
Size: 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... | 
Hits: 5148
Size: 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... | 
Hits: 3381
Size: 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... | 
Hits: 3151
Size: 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 ... | 
Hits: 2918
Size: 76.62 KB
Posted: 6/24/11
Flip the sender for access to its clips. |
Hits: 3029
Size: 77.21 KB
Posted: 6/24/11
Cut off the melted peg(s). | 
Hits: 2697
Size: 77.62 KB
Posted: 6/24/11
Release the catch and slide the plastic housing off the metal plate.
To make reassembly easier, t... | 
Hits: 2789
Size: 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... | 
Hits: 2711
Size: 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 ... | 
Hits: 3074
Size: 70.41 KB
Posted: 6/24/11
This is the board before cleaning... |
Hits: 2907
Size: 71.96 KB
Posted: 6/24/11
...this is after. DO NOT CLEAN the green areas since they provide the necessary resistance, and any ... | 
Hits: 2659
Size: 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... | 
Hits: 2587
Size: 82.47 KB
Posted: 6/24/11
Polish the area around the float arm pivot hole where the brass wipers will touch. | 
Hits: 2743
Size: 78.59 KB
Posted: 6/24/11
After reassembling the rheostat board, sender housing, wiper arm, & backing plate, press the arm bac... | 
Hits: 2984
Size: 93.35 KB
Posted: 6/24/11
Finally, check the sender's output over the full range, making sure it produces a smooth continuous ... |
Hits: 676
Size: 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... | 
Hits: 890
Size: 58.18 KB
Posted: 2/17/22
Since genuine level senders aren't available, imported copies will have to do. Fortunately, it's che... | 
Hits: 125
Size: 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... | | |
Fuel Level Sender Repair