AFM Web

Go Back   Ford Mustang Forums > Mustang Forums > Classic Mustang > Classic Tech
Welcome to AllFordMustangs.com. We look forward to you registering on our forum and making your first post.
Introductions| Mustang Lounge | Classic Talk | Classic Tech | Mustang Tech | Tech | Racing | Regional

Reply
 
Old 08-05-2009   #1 (permalink)
noworries is offline Rookie


Joined: Jul 2009
Posts: 6 Threads: 2
 noworries's Country Flag
Orange County   California
Default Need help figuring out fuel gauge not working

I'm working on my girlfriends 66 Mustang 289 Coupe. The fuel gauge is stuck on E. I took the wires off the back of the gauge and tried reading it with a multimeter, but I'm not sure if I'm using the right Ohm setting or what--but the reading is all over the place. I can't do anything to get a steady reading.

I searched and searched this forum, the whole internet, and the only other thing I found I could try was to ground out the connection at the sender and see if the gauge goes up. I played with that for a bit and got the gauge to go all the way over to F. So I figured the sender was bad. So the girlfriend picks up a new sender, and I've got her empty now. In preparation to replace the sender I figured I'd try it and make sure it worked. I put the plug on the new sender and then touched the sender to the fuel tank in case it needed to be grounded. I get nothing on the gauge. I tried grounding it out, and get nothing on the gauge. I tried putting the multimeter on the sender and the frame, and I get the crazy random readings.

I'm at a loss as to what to do to troubleshoot it further. Can someone tell me the right way to use a multimeter to troubleshoot this? Could it be a faulty connection at the plug? Should I cut the plug off and play with the bare wire and see if that fixes it? I'm at a loss and don't want to pull the old sender until I'm sure that's really the issue.

Thanks!
noworries is offline  
Digg this Post!Add Post to del.icio.usBookmark Post in TechnoratiFurl this Post!
Reply With Quote
Old 08-05-2009   #2 (permalink)
Print Dad is offline Made Member

Classic Member


Joined: Nov 2008
Posts: 631 Threads: 54
 Print Dad's Country Flag
Medford   Massachusetts
Default Need help figuring out fuel gauge not working

Hello noworries,
When it comes to electrical and electornics I stink but I think i can offer some advice, thanks to a friend who helped me.

I would take the sending unit wire off. Take a long wire with alligator clips on both ends.Clean the inside of the boot where the wire hooks onto the sending unit.
Attach one end of the wire to the inside of the plug (sending unit end) and the other end of the wire to a good. ground.
Now turn on the key, the gauge should go over to full.

We established the gauge works.

Shut off the key.

Next, take the end off the ground and attach it to the tank. Turn key to on position and see if the gauge goes up to full again.

This will tell you if the tank is grounded.
I am certain the sending unit need to be grounded to work, that much i know.

As another thought, you could try to hook the sending unit wire back on the tank, then try the ground wire with alligator clips and ground the tank. Then try the key but you would have to put some gas in it.

You may want to just install the new sending unit, they do go bad.


As for the Ohms and stuff I am clueless, but I know that you can check the gauge itself with my method. Then I would assume the new sending unit is good.

Just ideas from a back-yard mechanic.

Also caution when working with /near gas...... Print Dad
Print Dad is offline  
Digg this Post!Add Post to del.icio.usBookmark Post in TechnoratiFurl this Post!
Reply With Quote
Old 08-06-2009   #3 (permalink)
Veronica is offline Top Dog

Classic Member


Joined: Dec 2003
Posts: 5,011 Threads: 71
 Veronica's Country Flag  View Veronica's 30 photos  View Veronica's HomePage
Houston   Texas
Default

Hello. The reproduction sending units frequently don't work straight out of the box. If you still have the original Ford sending unit, odds are, there isn't anything wrong with it. It probably just needs a new float. The brass floats cost like 8 bucks. Again, if you still have it, try this. With the wire attached to it and the key in the on position, ground the front of the sending unit out on the car and then push the arm with the float on it all the way up. If the gauge pegs, you just need a new float.
Veronica is offline  
Digg this Post!Add Post to del.icio.usBookmark Post in TechnoratiFurl this Post!
Reply With Quote
Old 08-06-2009   #4 (permalink)
Ivy66GT is offline Made Member

Classic Member


Joined: Dec 2008
Posts: 1,008 Threads: 48
 Ivy66GT's Country Flag
Albuquerque   New Mexico
Default

Jason,

If you want to know the details of what to measure, etc., read http://www.allfordmustangs.com/forum...s-how-fix.html That may be too technical for you but I do give the resistance values, etc: 73-10 Ohms.

It might be your sender, it might not. If its only the float that is an easy replacement. With the wire off the sender if you still measure 73 Ohms to ground through the sender it might just be a float problem? I agree that the Ford sender is the best if its still usable. Turns out my car had so many bazillion miles on it that the little brass pad on the end of the sender potentiometer in the tank had completely worn away from sliding up and down every time the tank sloshes. Although I did 'fix' it as the above thread describes, the fix only lasted for a week or so and then I was back to where I started. The 4th picture I posted shows the internal contact and there is a brass pad mostly missing on the right end. If that is gone your sender is toast.

New Ford senders are disappearing if not already gone so I bought a new repro which turned out to be Scott Drake when I opened the box (their stainless, 5/16" version). As usual, I have mixed feeling about it. It has a 5/16" pipe like the original while most of them still have the 3/8" pipe used for '67(I believe?) and later. They also haven't figured out how to mount the pipe though since its bent at the wrong angle and almost prevents you from attaching the boot on the sender's external connection post. The float is also set about 1" too high so unless you bend it down the gauge reads zero until you have about 7 gallons in the tank making the gauge pretty useless.

The winding also isn't truly non-linear like the original Fords; picture 3 in the referenced thread. I was ready to send it back until I figured out the winding is composed of two linear windings of different pitch attached in series to make a piecewise linear approximation of the resistance vs float position instead of the original almost logarithmic winding. If you get it adjusted correctly its almost as good as the original although if they had just made in LIKE the original it would have been much better. It pegs out the gauge at 'F' about 3 gallons early which is about a gallon of so before the Ford unit did the same thing. Its physically impossible to measure the last gallon or so using this type of float since the float diameter causes it to bump into the top of the tank before the tank is full.

Not having measured one of the recently departed Ford senders I don't know if the ones from recent years were still wound like the ones from the 60s or not. Its possible the winding in a 90s Ford sender weren't truly original but similar to the one in the Scott Drake one I bought.
Ivy66GT is offline  
Digg this Post!Add Post to del.icio.usBookmark Post in TechnoratiFurl this Post!
Reply With Quote
Old 08-06-2009   #5 (permalink)
Veronica is offline Top Dog

Classic Member


Joined: Dec 2003
Posts: 5,011 Threads: 71
 Veronica's Country Flag  View Veronica's 30 photos  View Veronica's HomePage
Houston   Texas
Default

Hi again. 40+ years is a long time to be submerged in gasoline. Occassionally, it actually is the sending unit itself that fails, but, on cars that have been driven periodically, and the gasoline didn't just sit there for twenty years turning to varnish, it's far more common to have the problem turn out to be the float. I'm pretty sure that NPD still has Ford fuel sending units, but they are the post-68 units with the 3/8 outlet tube.

As a side note, Ivy66GT, these guys make stunningly nice decals and stuff. You can't tell them from the real ones, except for the way that they're brand new.
ECS Automotive Concepts | (636)-207-7767 | Factory EXACT Reproductions!
Veronica is offline  
Digg this Post!Add Post to del.icio.usBookmark Post in TechnoratiFurl this Post!
Reply With Quote
Old 08-06-2009   #6 (permalink)
Ivy66GT is offline Made Member

Classic Member


Joined: Dec 2008
Posts: 1,008 Threads: 48
 Ivy66GT's Country Flag
Albuquerque   New Mexico
Default

Quote:
Originally Posted by Veronica View Post
As a side note, Ivy66GT, these guys make stunningly nice decals and stuff. You can't tell them from the real ones, except for the way that they're brand new.
ECS Automotive Concepts | (636)-207-7767 | Factory EXACT Reproductions!
If only someone would start make stunning exact repro PARTS!!

I first tried ordering a gauge sender from NPD and they have changed their offerings although their online catalog doesn't tell you that. I understood they had no Ford senders and the last ones went for something north of $200. I know that VCM had sold their last one.
Ivy66GT is offline  
Digg this Post!Add Post to del.icio.usBookmark Post in TechnoratiFurl this Post!
Reply With Quote
Reply



Thread Tools


sponsors

Mustang Photos
Add to Favorites    Link to us    Contact    Directory    Site Rules    Archive    Terms of Use    Privacy    Top Sites    RSS    Meet Our Sponsors    Advertise   
AllFordMustangs is not affiliated with or endorsed by Ford Motor Company. ©Copyright 2002-2010 All Auto Enthusiasts Network

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112