Hey there Gary, thank you for the detailed write-up and your process. I'm sure this will help others should they run into the same situation. Again, thank you for sharing. Let us know how your test of repair turns out.This is a follow up on what I did so far about my fuel level sensor.? I ordered one on eBay that is said to be an ACP brand and has the part number C7OZ-9275-B.? It was the one that looked closest to the one that was in my tank.? After much discussion and search, I came to believe the old one in my tank was the original from the factory or at least an OEM replacement.

The new one did not look exactly like they show on eBay but seemed to have the best features of all the units I looked at.? It is made of stainless steel, has a black wire (instead of yellow) going from the variable resistor to the wire connector, and the stops on the variable resistor for the float rod are the gate type instead of the tab type (as shown on eBay).? Otherwise it looks the same.

One thing I didn't like about it was it was difficult to keep the seal in place when installing it in the tank and it was difficult to see if it was in position once the sending unit was in place.? I did finally get it in place only to discover the lock ring would not engage without compressing the seal a little.? The seal was stiff enough that it was difficult to compress.? After struggling with it for a while I did get the locking ring engaged and was able to rotate it to the locked position.

I checked the ohm resistance from empty through full positions before I installed it in the tank.? The transition was smooth throughout the range and had similar ohm values as the old sending unit.? I drained very close to 4 gallons out of the tank before removing the old sending unit.? The fuel gage was reading just under 1/4 with the fuel in it.? After installing the new sending unit, I checked the fuel gage with no fuel in it and it was exactly on the E line.? I dumped in the 4 gallons and the gage was reading just a hair over the E line.? I then drove to the gas station I like to fill up.? I estimated I still had about 3 gallons left in the tank when I filled up and was able to put 17 gallons in it.? So, I learned my tank does hold 20 gallons.? The gage read just barely under F after filling.

So, I am pretty close to what I like reading on the fuel gage with this new sending unit.? I am thinking the problem I had when I ran out of gas, while I thought I had plenty of reserve fuel left in it, was due to the float.? As I explained before, the skin on the float was partially deteriorated, but the foam inside appeared to be close cell and still should have worked.? I am now thinking the foam may still have gotten partially soaked with fuel and lost part of its buoyancy or is lost enough of the foam to allow it to sit lower in the fuel or a combination of both.

I still plan to put fuel in a gallon can and place the old sending unit in there to see if my fix on the float and screen works.? I will also observe how the float functions.

Gary in SoCal.

-----Original Message-----
From: [email protected] <[email protected]> On Behalf Of Chris Scheers
Sent: Friday, January 03, 2020 11:40 AM
To: [email protected]
Subject: Re: [fairlaneregistry] Fuel level sensor

Ah, I see.? Looking at pictures it appears that the wagon and Ranchero use the brass float while the cars use the black float the looks and feels like it was carved out of charcoal.? Does that sound right?


At 04:04 PM 1/2/2020, Gary Wittman wrote:

>My float has the arm wire going through through the center of it along
>the length of the float.? The wire has a clip looking device
>that keeps the float from sliding off the wire.?? It looks like the
>float could be replaced but I can't find a float available like that.
>I could buy a sending unit that has the copper float and they look like
>they could be replaced with the ones on those links, that snap into the
>hook.
>The sending unit I am looking to buy has a float that is very much like
>mine.? They say they make all kind of vintage reproduction sending
>units and have for 30 years.? This one has the 3/8" pickup for the 428
>CJ engine.? It looks like mine in everyway except it has a wire with
>insulation going from the electrical connector to the variable
>resistor.? Mine just has a metal strap with no insulation.
>
>Gary in SoCal
>
>-----Original Message-----
>From: [email protected] <[email protected]> On Behalf
>Of Chris Scheers
>Sent: Thursday, January 02, 2020 11:15 AM
>To: [email protected]
>Subject: Re: [fairlaneregistry] Fuel level sensor
>
>Interesting.? I recently had the sending unit out of my '69 wagon and
>those floats appear to be compatible with it.
>
>The float arm is wire and has a hook at the end that the float snaps into.
>
>Is yours different?
>
>I know that the SW sending unit is different from the other models.
>
>
>At 11:24 AM 1/2/2020, Gary Wittman wrote:
>
> >Chris,
> >
> >I saw those floats but they are not compatible with my mine.? They
> >work with a newer style sending unit.? I have found a new sending
> >unit that is made by APC which looks very much like my original
> >sending unit.? I will probably order that one.
> >
> >Gary in SoCal
> >
> >-----Original Message-----
> >From: [email protected] <[email protected]> On
> >Behalf Of Chris Scheers
> >Sent: Tuesday, December 31, 2019 4:02 PM
> >To: [email protected]
> >Subject: Re: [fairlaneregistry] Fuel level sensor
> >
> >At 11:12 AM 12/31/2019, gary.wittman@... wrote:
> >
> > >I finally got around to removing the fuel level sensor out of the
> > >tank to see if anything was wrong with it. The screen was falling
> > >apart at the seam and the float was partially compromised.
> > >The screen consisted of two layers and each layer was still intact.
> > >I rotated the screen layers so the seam gaps were not aligned and
> > >used zip ties on each end to hold them in place on the intake tube.
> > >I synched the zip ties very tight so they would not slip off, and I
> > >hope the fuel does not cause them to relax.? I also put one zip tie
> > >loosely around the middle to stabilize the gap there.
> > >The float was in good shape for the most part but on one end some
> > >of the outer skin was broken off at the edge.? The foam underneath
> > >appeared to be close cell but was kind of eroding out of there.? I
> > >applied a thin layer of epoxy over the exposed foam with a little
> > >overlap onto the intact skin.? I felt this would help to keep the
> > >foam from deteriorating more.? Of course the best thing to do would
> > >be to replace the float, but I doubt those are available by themselves.
> > >I will probably order a new fuel level sensor unit as a back up in
> > >case my repair does not work.? My fuel gage was reading just under
> > >1/4 and I drained out about 5 gallons.? I will see if the gage
> > >changes after the repair.
> >
> >
> >Not all epoxies are gasoline safe.? Some will deteriorate.
> >
> >New brass floats are available.? Here are a couple.
> >
> >https://urldefense.proofpoint.com/v2/url?u=https-3A__www.dennis-2Dcar
> >pe
> >nter.com_en_trucks_fuel-2Dsystem_gas-2Dtank-2Dsending-2Dunit_68-2D927
> >5-
> >2Df-2Dgas-2Dtank-2Dfloat-2Dbrass-2Dp65&d=DwICAg&c=euGZstcaTDllvimEN8b
> >7j
> >XrwqOf-v5A_CdpgnVfiiMM&r=N8oEXv3gdNIkwN69ThQUPVlE_vq-tSNUrzZ9bSiy8BE&
> >m=
> >cqC3QyD_y6NP0hH0FARVUUC3lHQc69W6R-59xaOqopA&s=-W-d6-DKSuSCIqXYYQptngx
> >Qu
> >gGv1WBPz-CW70_fMcA&e=
> >
> >https://urldefense.proofpoint.com/v2/url?u=https-3A__www.amazon.com_B
> >ra
> >ss-2DFord-2DFuel-2DSending-2DUnit-2DFloat_dp_B01GFDB428_ref-3Ddp-5Fcs
> >x-
> >5Fsw-5Fimage-5Fcsd-5F0&d=DwICAg&c=euGZstcaTDllvimEN8b7jXrwqOf-v5A_Cdp
> >gn
> >VfiiMM&r=N8oEXv3gdNIkwN69ThQUPVlE_vq-tSNUrzZ9bSiy8BE&m=cqC3QyD_y6NP0h
> >H0
> >FARVUUC3lHQc69W6R-59xaOqopA&s=Q7pwOjqCWwLVLEWcHJIsiuCEYB1KXLAbf9z5bT7
> >yq
> >9E&e=
> >
> >There are also plastic ones in the after market.? I don't have any
> >experience with them.
> >
> >I don't know how well zip ties will hold up to gasoline.? Please
> let me know.
> >
> >I normally take off the sock/screen and throw it away.? They tend to
> >fall apart and the pieces can plug the fuel system.
> >
> >Whether or not you remove the sock, I recommend putting an inline
> >filter between the hard line and the fuel pump.? There are some clear
> >ones that are handy to tell if you actually have fuel making it to the pump.
> >
> >I was concerned about the longevity of these plastic filters, but
> >some of the ones I have have been going for over 10 years now.

-----------------------------------------------------------------------
Chris Scheers, Applied Synergy, Inc.

Voice: 817-237-3360??????????? Internet: chris@...
?? Fax: 817-237-3074