Sylvie Willis
The fuel float is a component of the fuel pump that sends a digital reading to the instrument cluster on your dashboard. It can become clogged with debris and need replacing. This is a simple mechanical failure. To replace the fuel float, you will need to disconnect the negative battery cable, raise and safely support the vehicle, and disconnect the oil pressure sensor electrical connector. You will also need to measure the tank depth from the top of the tank to the bottom, trim the sending unit arm to match the tank depth, and fasten it with setscrews to the flange of the new sending unit.
| Characteristics | Values |
|---|---|
| First step | Measure tank depth from the top of the tank, near the sending unit, to the bottom |
| Second step | Trim the kit’s sending unit arm and match it to the tank depth |
| Third step | Cut the float arm to the correct length and fasten it with setscrews to the flange of the new sending unit |
| Fourth step | Remove the three wires on the back of the old gauge |
| Fifth step | Remove the fuel gauge |
| Sixth step | Install the new sender by lowering the float and float arm into the tank |
| Seventh step | Slide a new gasket into place under the flange, then align the gasket with the holes in the sender and in the tank |
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What You'll Learn
- How to measure tank depth to determine the length of the sending unit's float arm?
- How to trim the sending unit arm to match the tank depth?
- How to fasten the float arm to the flange of the new sending unit?
- How to remove the wires on the back of the old gauge?
- How to lower the float and float arm into the tank?
How to measure tank depth to determine the length of the sending unit's float arm
To measure tank depth to determine the length of the sending unit's float arm, you must first measure the tank depth from the top of the tank, near the sending unit, to the bottom. This measurement determines the length of the sending unit's float arm.
For example, if your tank is 15.5" deep, the shaft of the sending unit should be half that plus half an inch, so 8.25". You can then cut the kit's sending unit arm to the correct length. These usually come in 24" lengths and can be trimmed with a strong pair of wire cutters or a hacksaw.
You can also use a swingarm electric sending unit, which gathers fuel level information in the same way as a mechanical sending unit. To do this, measure the tank depth, minus one inch, and make the swingarm the correct length.
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How to trim the sending unit arm to match the tank depth
To replace a fuel float, you will need to first measure the tank depth from the top of the tank, near the sending unit, to the bottom. This measurement will determine the length of the sending unit's float arm.
Next, trim the sending unit arm to match the tank depth. Sending unit arms usually come in 24-inch lengths, and you can use a strong pair of wire cutters to cut through most units, but some will require a hacksaw. Once you have cut the float arm to the correct length, fasten it with setscrews to the flange of the new sending unit that will be screwed into the top of the tank.
The sending wire will come off a post in the centre of the flange. You can then lower the float and float arm into the tank, making sure to slide a new gasket into place under the flange. Align the gasket with the holes in the sender and in the tank, and mark it in relation to the flange as it may turn while you are centring the screw holes to match the tank holes.
The float is designed to send a digital reading to the instrument cluster on your dashboard. When the float moves, the rod attached to the float moves across the coil, connecting a different resistance pattern. If the float is lowered, the resistance pattern is low and an electrical current is quick to move. If the float is raised, the resistance pattern is high and an electrical current is slow to move. The fuel gauge is designed to register the resistance of the fuel gauge sender. As the resistance is lowered all the way in the sender, the fuel gauge will register E or empty. As the resistance is raised all the way in the sender, the fuel gauge will register F or full.
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How to fasten the float arm to the flange of the new sending unit
To fasten the float arm to the flange of the new sending unit, you must first measure the tank depth from the top of the tank, near the sending unit, to the bottom. This measurement determines the length of the sending unit's float arm. Next, trim the kit's sending unit arm to match the tank depth. Once you have cut the float arm to the correct length, fasten it with setscrews to the flange of the new sending unit.
You can also use a propane torch to unweld the float arm from its hangar and braze it onto the new sending unit. You can use a pill bottle to do this: grind the most outer part of the cap off and cap retainers on the bottle. Epoxy glue the cap to the bottle, then drill holes in each end and epoxy to the lever rod. Finally, put a whole coat of epoxy over the entire bottle.
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How to remove the wires on the back of the old gauge
To remove the wires on the back of the old gauge, first measure the tank depth from the top of the tank, near the sending unit, to the bottom. This measurement determines the length of the sending unit’s float arm. Next, trim the kit’s sending unit arm—they usually come in 24-inch lengths—and match it to the tank depth. A strong pair of wire cutters will work with most units, but some require a hacksaw. Once you have cut the float arm to the correct length, fasten it with setscrews to the flange of the new sending unit that will be screwed into the top of the tank.
The sending wire will come off a post in the centre of the flange. There are three wires to remove. One wire goes to the centre pin on the tank sending unit, one goes to the ground, and the third connects to a 12-volt source, normally the ignition switch. Remove the fuel gauge.
The fuel gauge is designed to register the resistance of the fuel gauge sender. As the resistance is lowered all the way in the sender, the fuel gauge will register E or empty. As the resistance is raised all the way in the sender, the fuel gauge will register F or full. When the float moves, the rod attached to the float moves across the coil connecting a different resistance pattern. If the float is lowered, the resistance pattern is low and an electrical current is quick to move. If the float is raised, the resistance pattern is high and an electrical current is slow to move.
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How to lower the float and float arm into the tank
To lower the float and float arm into the tank, you must first remove the three wires on the back of the old gauge. One wire goes to the centre pin on the tank sending unit, one goes to ground, and the third connects to a 12-volt source, normally the ignition switch. Remove the fuel gauge.
Next, slide a new gasket into place under the flange, then align the gasket with the holes in the sender and in the tank. When the gasket is aligned, mark it in relation to the flange, as it may turn while you are centring the screw holes to match the tank holes.
The sending wire will come off a post in the centre of the flange. Once you have cut the float arm to the correct length, fasten it with setscrews to the flange of the new sending unit that will be screwed into the top of the tank.
When the float is lowered, the resistance pattern is low and an electrical current is quick to move. If the float is raised, the resistance pattern is high and an electrical current is slow to move. The fuel gauge is designed to register the resistance of the fuel gauge sender.
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Frequently asked questions
First, measure the tank depth from the top of the tank, near the sending unit, to the bottom. This measurement determines the length of the sending unit’s float arm. Next, trim the kit’s sending unit arm and match it to the tank depth. Once you have cut the float arm to the correct length, fasten it with setscrews to the flange of the new sending unit that will be screwed into the top of the tank.
You will need a strong pair of wire cutters, or a hacksaw, and setscrews.
A fuel float is a float located on the fuel pump that sends a digital reading to the instrument cluster on your dashboard.
