92 Exploder fuel gauge
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Junior User
Joined: Oct 2002
Posts: 85
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From: Houston
92 Exploder fuel gauge
Need help guys, I just bought a 92 exploder and invested alot of time and effort getting it in reliable running condition:-. Now I just have 1 more problem to tackle. The fuel gauge is on E, always. I called to check the price of a sender and it only comes with a fuel pump, the local ford guys tell me it's all one assembly costing $175.00 the local parts store offers one for $110.00. Is there any way I can remove the old one from the tank and fix it without buying a new one? Does it have a plastic float that i can epoxy or a metal one I could solder assuming it has a hole in it or is it some type of a foam float that I can rig?
I am assuming it's the sender and not the gauge in the dash
Is there any way I can check the gauge to see if it works without removing the tank? If it does happen to be the sender in the tank how do you remove the tank and is there any special tools required?
Thanks in advance for any help
I am assuming it's the sender and not the gauge in the dash Is there any way I can check the gauge to see if it works without removing the tank? If it does happen to be the sender in the tank how do you remove the tank and is there any special tools required? Thanks in advance for any help 
Elder User
Joined: Aug 2002
Posts: 886
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From: Cincinnati
92 Exploder fuel gauge
I don't really remember the float when I replaced the pump but on several message boards they say this common problem is a result of a leak in the brass float. Doubt it is a problem with the sender because an open sender will indicate full. It has been reported that these floats are available for $5. If you fix it yourself, unsolder the vent hole at the end, resolder the seam, and then reseal the vent. Use an electric iron.
Elder User
Joined: Aug 2002
Posts: 886
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From: Cincinnati
92 Exploder fuel gauge
Every brass float has a pin hole with a dab of solder on it. If you heat up the seam to repair a crack, the hot air expanding inside the float will prevent a good solder joint. That's why they put a vent hole in for manufacturing. After the assembly has cooled they quickly put a small dab of solder on the vent hole to seal it. If you don't the float will crush when it cools. Also use an electronic 60/40 solder for the repair. It melts at a lower temperarure than the solder they used to put it together.
New User
Joined: Jan 2003
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92 Exploder fuel gauge
Originally posted by Sid Daley
me posting it, appears to be a glitch in the forum software.
Sid
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Fleet Mechanic
Joined: Aug 2002
Posts: 1,899
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From: Raleigh USA
92 Exploder fuel gauge
I wouldn't recommend trying to repair the float. They are only $5 at a ford dealer. If the repair doesn't hold, you will have to pull it back out which IMHO is WAY too much work to save 5 bucks. Also make sure you have the correct fuel line tool to disconnect the lines at the pump. I have done about 3 of them and they ain't the easiest pump to do. Just my .02
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Elder User
Joined: Aug 2001
Posts: 942
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From: South Texas
92 Exploder fuel gauge
91-95 models are roughly similar according to Haynes manual. In order to replace float, the tank must be dropped as fuel pump/sending unit drops into tank from the top. The most miserable part is removing the tank/shield support bolts which are long and may be rusted in. A can of penetrating lube and air tools would make the job much easier. The sending unit cannot be purchased seperate from fuel pump. Go figure, as it is held onto mounting bracket with 2 small screws. If you replace the float, a word of advice. DO NOT reassemble without checking sending unit operation first, otherwise you may be dropping tank second time, as I did, to replace the pump/sending unit.
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