Fuel gauge - have I killed it?

[splatt4001]

I know there's a lot that's already been said about fuel gauge problems on this forum, but I can't see a solution to this particular problem. Can anyone help...?

My gauge (1996 diesel 2wd freda) was showing full fine. But it never went below a quarter (which was interesting when I ran out in the middle lane of the M4, with cones on the hard shoulder, going uphill... ).

Anyway, I made a new earth connection. No change.

So, bought a sender unit off ebay (2nd hand but looked OK). Before installing it properly into the tank I wired it up to the existing plug and my new earth to test it fixed the problem. And it did. The gauge went right down to - and beyond - empty when I put the float in the DOWN position.

Then I flipped the float right UP to simulate full. Result - nothing. The gauge stayed on empty (igintion was on). So I tried making a new earth connection. Still no joy.

Assumed this 2nd hand sender was duff, so wired my old sender back in. And now that won't move the gauge off empty. Disaster.

I can only think that I may have somehow blown something in the gauge when I tested the float manually - perhaps the gauge can't cope with the float moving quickly.

Can anyone advise? Anything else I could test to identify where the fault lies? I don't see that there is a fuse just for the gauge.

Thanks.

Sam

[jaylee]

Hi sam,
Just a thought.. The fuel gauge works without the ignition on showing the amount (aprox) in the tank.. It does on mine.

Have you checked the continuity of the wiring? There could be a short?

Sorry i can't think of any more ideas, been used to dodgy gauges on Bedford's & Vauxhalls for years.. Its nice to have a fuel gauge as near as damn it on this one!!

[waycar8]

I doubt you will get a correct reading doing it like that just plug it in and leave it, when you fill up it takes a while for it to move up to the full posistion anyway so pushing it up with your finger wont make it register any quicker.

It wont harm anything by putting it in and leaving it half an hr to check make sure it is duff or working perfectly

[maxheadroom]

this may help.

http://www.igmaynard.co.uk/bongo/forum/ ... uge#p84286

PM sent

[jaylee]

this may help.

http://www.igmaynard.co.uk/bongo/forum/ ... uge#p84286

PM sent

Nice one Max, i was trying to find that link...!
And very detailed it is too!

[splatt4001]

Thanks for all the v helpful replies - and that last link.

Now I think understand. I was assuming that it was all about getting an excellent earth connection from somewhere on the sender unit. But if I understand correctly what is crucial is getting a connection from the negative of the float resistor. I've taken the sender unit out now and put a wire direct from the screw that holds the plastic float resister housing on. And re-done the wire that was already soldered on to the float. Waiting for the araldite to set to block the hole uo. Then it's time to test.

I was surprised to see that the long tube in the sender unit (the one with the black thing on the end) was quite bent (not just at the mid point, but below also). The unit I got off ebay did not bend at the end. I wonder whether that's been damaged - anyone know whether it should bend that much? I'll try and upload a pic.

Sam

[splatt4001]

Right. Just installed the re-wired sender unit. And IT WORKS as before.

But, am now certain that the tank has been squashed - which is why the gauge won't go down to zero.

So I'm in the market for a new fuel tank. Found one in Wigan and one in Sussex. But if anyone nearer Bath just happens to have a fuel tank for sale, please let me know. The vehicle is a 1996 Ford Freda, 2wd diesel auto.

Thanks again for all the help and advice.

Sam

[Dolly1]

Hi Sam
Have you tried Bell Hill Garage,they are always breaking Bongos,at Norton St Phillip,just down the road.

Beat ya to it Jaylee

[jaylee]

Have you tried Bellhill near Bath...? well, out Tuckers Grave way, Norton St Phillip.

Damn!!

[mikeonb4c]

How on earth doeas a tank get squashed?

[Simon Jones]

Changing the tank seems like a long shot unless it is obviously damaged. I would be tempted to leave it alone & just be aware of how the guage behaves & fill up accordingly.

[splatt4001]

The tank has definitely been crushed. Possibly jacked up under there? Or grounded?

Anyone know how easy/hard it is to change a tank - doesn't look too bad.

Sam