This is why a fuel sender dies. (with pic)
So what needs to be redone to have oe style quality? Carbon button? Better resistance wire? Can't be that hard. I'd rebuild an oe I'd that's what it took and was possible
Looks like mostly the point where the button (used to be copper or maybe nickle) and probably the quality of the resistance wire wrap.
The button would probably be pretty easy to add, and bending the metal contact back a little as to not add more pressure on the resistance wire.
The BIG problem would be finding that same resistance wire to re wrap with.
I imagine it has to be measured by amount of resistance drop per inch or something like that.
It must be out there somewhere or repair places couldn't repair them.
Aren’t the OE ones wrapped differently than the reproductions? Something about the resistance varying over the throw of the pickup to account for the non-linear way the volume of the tank drops because of the spare tire cut out?
Also pretty sure there’s a guy back east that rebuilds the OE senders, they’d have to be better quality than the reproductions. I’ve seen his contact info on here somewhere.
Although that said the one in my Duster has been working fine. It’s not accurate to the amount of fuel, ie, 1/2 a tank doesn’t mean 1/2 a tank. But it’s consistent, and I drive it enough to know how what the gauge shows corresponds to what’s left in the tank. Plus it’s a 3/8” sender, although I’m sure there’s some way to pair the OE guts with a larger tube...
Exactly, and the insulator seems to have small notches in it's edges where the wire wraps just for that difference.
I have an aftermarket gauge, but it's ohm range is the same as OE Mopar and some Fords use, so I can still order the OE Mopar sender and they are real close in the reading.
What I care about most is knowing exactly when empty is, so being a little off in the middle of the gauge (if it is) doesn't bother me.
I have a 13 gallon tank and if I put 6 gallons of gas in it the gauge shows pretty much exactly 1/2 tank.
If I fill it all the way it shows exactly on the full mark.
That's close enough for me.
