Fuel Sender
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Joined: Mar 2004
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Fuel Sender
Hey, I'm new to this board as I am soon buying a '96 Bronco XLT 5.8 from my dad. The Bronco has a couple of issues, but the one that most perplexes me is the fuel sender. The fuel gauge went a while back, and after looking at many discussions on boards similar to this one, it has come to my attention that this is a very common and recurring problem. I know this has probably been discussed a million times on this board, but upon searching I couldn't find an answer to my exact question, so here goes.
I know that I must remove the fuel tank to get to the sender, which is attached to the fuel pump, and all that stuff. I realize that the new sender will probably cost me $100-250. However, has anyone who's done this tried a specific kind of aftermarket sender or in general a better built one that won't crap out again in a few years? From the way it sounds, these senders just don't last, and I'd rather spend that money on something that might last longer.
Thanks in advance, and I'm sure I'll be picking your brains once I drive this Bronco around a bit.
I know that I must remove the fuel tank to get to the sender, which is attached to the fuel pump, and all that stuff. I realize that the new sender will probably cost me $100-250. However, has anyone who's done this tried a specific kind of aftermarket sender or in general a better built one that won't crap out again in a few years? From the way it sounds, these senders just don't last, and I'd rather spend that money on something that might last longer.
Thanks in advance, and I'm sure I'll be picking your brains once I drive this Bronco around a bit.
Senior User
Joined: Mar 2004
Posts: 146
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From: Norristown, PA
This happened to me back in January. I thought it was the gauge, but the dealer said the problem was in the tank. Since I had an old style fuel pump with an integrated sender, the dealer had to install a new redesigned fuel pump. It did fix my problem, but it just acted up again and I had to take it back to the dealer and they had to install another sender. I haven't filled my tank yet, so I don't know if the gauge will read FULL.
Posting Guru
Joined: Jul 2003
Posts: 1,486
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From: Independence, MO
I'm not shure if there is a solution for this the asy should run about $100-110. i think the biggest problem is that it is a 33gal. tank and when half full they slosh so hard they will rock the whole truck and in just a few years they eventualy beat the sending unit to death, this used to be a big issue on big truck years ago because of the enormus size of the fuel tanks, but the eventualy came with with a better design for it. hope this helps DW
Senior User
Joined: Jun 2003
Posts: 101
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From: North Carolina
i've got the same problem. my sending unit is beaten up pretty badly, and i agree with DW...they just don't last. my solution has been to look into baffled fuel cells/tanks, and a complete re-work of the fuel sending/sensing system. seems i'll just keep replacing stock units, or upgrade it to not-easily-breakable status.
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