1984 XJ6 Vanden Plas, Federal. I had a problem with the fuel sender. The float was filled up with fluid. Bought an aftermarket one from Barrett. Could never get the damned thing to work. First, it requires the float arm be bent. How you bend it. I dunno just guess? Take it out and try to bend to match it to the original one. Still not good. Reached 1/2 tank and never went higher even with a top off. OK, had enough of that ****. Get a new float. The little rubber thing on the end of the float, like an elastic cap, crumbles. But replace the float, install the old one in exactly the same way as original ( I know because I marked the original when I took it out). Guess what. Add 2 gallons of gas and it doesn't register anything. So I guess it needs to come out again. GRRR. That's four times this assembly will have been removed and reinstalled.

Question, since I am tired of pumping gas out of the tank, is two gallons of gas going to over top the hole when the sender is removed? Second, question, the sender has two travel limits. One is much shorter than the other. I assumed the larger travel arc goes up and that the shorter travel arc goes down. Is this right?

 

I feel your pain brother. A suggestion: hook it up outside of the tank and move it by hand and watch the needle move on the guage. If it dosen't go from full to empty when moved by hand there is to much resistance along the circuit or the guage is defective. Usually I get things right on the third attempt. My wife says "Are you up to three yet?" when I complain about something.

Jeff

 

the float floats up as the tank is filled, down as the tank is emptied, same as the old toilet tank floats.

 

Hi Jose

I get that. But there is an arc. Assuming a 90 degree angle from the mounting plate, the arm travels either direction. In one direction it deflects perhaps 10-20 degrees. The other direction it deflects 50 -60 degrees. The question is which deflection is right? I assume the larger one should go up so the float can reach the top of the tank. Unless, the sender is already at the top of the tank in which case a larger deflection down would be right. Looking at where the sender is on the tank I assumed it needs to rise higher. I am just asking for confirmation of that.

 

yes I understood your question.

Logic tells me the larger movement would be down, and the shorter up.

if you visualize where the sender is sideways in the tank, it is mounted almost two thirds up in the tank. So it needs more movement downwards than upwards. Just my opinion, I could be wrong.

 

Hi,
When I replaced my floats I managed to install them both backwards the first time so I feel your pain ! They jammed inside the tank. I THINK you can remove the senders with a couple gallons left without spilling out, I did by mistake, but be careful !
Here are some pictures of my original senders and the Jeep CJ6 floats that were a perfect fit ! Cleaned them by soaking in "cleaning vinegar" ( higher % than cooking ).
Red socket is left, white is right. 18 ohms full - 250 empty.
They both mount the same way = round insulated wire connector ( red or white ) to bottom, float arms at top and on both on left side ( facing front on car ). The arms / float mounting are the only difference, they are bent opposite directions.
Also shown, tool I made from PVC fitting + pipe section slotted with dremel to fit mounting rings.


Top ( red ) is uncleaned left, bottom ( white ) cleaned, both with bad floats. Custom tool for lock rings to left.

Left side cleaned with new float. Top up - as mounted in tank.

Floats for CJ6, perfect match !

 

I'm with Jose on this one. I don't know if you've had the tanks out, so I sent a some-what helpful pic of one of my tanks when it was out. Sender is mounted about in a straight line from the roll of paper towels to the back of the tank (this is the high-tech description). Float would drop more to reach the bottom than rise to reach the top. I'm sure you have found out that the senders are "handed".

Dave

 

A series two sender in a series three tank only goes to 5/8 full. Has about 4 gallons left when it hits “E”. I have series three tanks in a series two car. I used the old senders.
not sure if this information adds to your mystery.