$20 Fuel Sender and Modification Howdy folks!

This guide is for replacing your old fuel sender for your gas or diesel and modifying the shower head.

Parts Needed Per Tank:

Fuel Sender Amazon link:

8 inches 5/16 biofuel hose
1 5/16 Brass T barbed
10 #4 hose clamps
Wire connector
Electric tape

Tools Needed:
Wire Cutters
Wire stripper
Soldering Iron (Up to you for connecting wires)
Solder
Drill 3/32 Drill bit
Wire brush/wire wheel
​​​​Contact cleaner

Step 1. The fuel sender unit will be rusted pretty badly when you remove it. The first thing you will want to do is remove all the rust off the unit. Use the wire brush and wheel and get as much of it off as you can. I used a wire brush and used dawn soap while washing it to help break it down as I scrubbed. The top of the unit where it meets the seal is most important to be clean, that way it seals properly when put back together.



Remove the fuel sender carefully, then cut the wire about mid way. Then continue cleaning the plate behind the fuel sender. This is important as it makes contact with it and needs to be clean for little friction and to provide a good seal.



Back side cleaned good. Make sure to clean the other side where contact is made with the ohm resistor!

Step 2. The fuel sender unit from Amazon comes with its own backer plate. This will NOT be used. It is slightly to big, and would have to be welded on. The easiest method is to clean the original back plate and reuse it.

Once the metal backing plate is clean try fitting the fuel sender into it. Place the side with one clip first, then pop the side with the two clips. The hole for the bobber wire may be two small as was in my case. I drilled it out a bit with a 3/32 drill bit for it to fit.




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Step 3. Install the fuel sender into the backing plate and cut the tip off of the wire. It is the wrong connection for my diesel sender, if it works skip this step. I then soldered the two wires together from the fuel sender. Using a wire crimp with a heat gun is more ideal. Used what I had.

That finishes the fuel sender portion of this guide. Super simple and cheaper than a motorcraft sender for $100.

Shower Head Modification:

The shower heads on the fuel senders always fails and breaks off. This means that if you have a quarter tank of fuel still you can stall out because it will not pick up the fuel from the bottom of the fuel tank. They typically break over time from getting brittle or from fuel sloshing in the tank and snapping them off. Steel shower heads are sold but expensive. This is a common modification that is fool proof and guaranteed to never break and costs less than $10.

Step 1. Cut 5/16 rubber fuel line to about 5" to 6" long.
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​​​​​​Step 2. Lubricate the inside of the hose with oil or a wet finger, then slide it onto the positive fuel sender about an inch where it pulls fuel.

Step 3. Using a #4 hose clamp clamp it onto the fuel sender nice and tight. Then use a 5/16 Brass barbed T and clamp that onto the end of the line.

Step 4. Take a picture of your unit and post it here!

 

You have an extra http in the link so it doesn't work

 

Thanks for the catch. Fixed it. I had written everything before posting on here and it gave me some issues pasting everything.

 

bad quality pic but this is only being posted since im trying to ID this tank or sender or something, you think this could be a ford style sending unit? Its a brass float and carb style unit, but it screws into a plastic tank. Its shaped like a saddle tank, mostly, but I cant find anything GM like remotely close to it. Nothing on the sending unit except a stamping indicating what the feed hose is.