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Fuel sender repair
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Yannvanh
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Joined: November 07, 2020
Posts: 215
Location: Belgium
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PostPosted: Tue Oct 28, 2025 4:31 pm    Post subject: Fuel sender repair Reply with quote

Next on my project was the gas tank/fuel sender.

Did a test on my fuel sender but it was heavily corroded.
So gave it a shot and tried to repair.


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Started to take it apart and clean al the components!

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Originally it was riveted but i took a copper bolt and gave it a try


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Made a gasket so no fuel would leak at the connector.

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Then started building it up:

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A bakelite washer to avoid contact from positive to ground:


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Metal washer on top:

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I soldered the cable back (hard to see in the pic)

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Put everything back together and give it a test!

Empty tank:

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3/4 tank:

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I need to order a fuel gauge so i can test it on a gauge itself but i think i did a good job!
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BarryL Premium Member
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Joined: November 01, 2004
Posts: 15446
Location: Casa de Oro, California
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PostPosted: Tue Oct 28, 2025 6:34 pm    Post subject: Re: Fuel sender repair Reply with quote

I especially commend you for the nichrome wire part.
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@Buswerx
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Joined: October 26, 2021
Posts: 24
Location: San Luis Obispo
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PostPosted: Fri Nov 14, 2025 11:13 pm    Post subject: Re: Fuel sender repair Reply with quote

Wow
Lots of work and patience

Good work
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matthew henricks
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Joined: January 02, 2002
Posts: 1401
Location: So. Cal
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PostPosted: Tue Nov 18, 2025 8:18 am    Post subject: Re: Fuel sender repair Reply with quote

Very nice. Something many would never even consider. Love it!
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Douglas Denlinger
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Joined: May 23, 2003
Posts: 1410
Location: Arizona's version of the east coast
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PostPosted: Wed Nov 19, 2025 8:59 am    Post subject: Re: Fuel sender repair Reply with quote

I knew there was a reason I have held on to all the originals that were removed from customers buses that were not working over the years.....something to do during retirement! Nice work!
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