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Discussion Starter #1
This might be a dumb question, but I'm replacing the fuel tank in my '96, the old one developed a leak, but should I replace the sending unit while I'm swapping tanks? It has just over 100k original miles. The one I have is fine now, gauge works great, but I don't really have a ton of money to spend, and I heard new sending units can be expensive and I'm not sure which parts I would have to order from LMC. If anyone has ordered one before can you post a link or something? What would be a good price for one? Thanks
 

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IIRC they go for around $100.00, I didnt replace mine when I installed a new tank. (my guage was dead do to a hole in the float, replaced float and its been all good) Thats been a couple years ago.
 

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1995 XLT SAS w D44 and D60 rear
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The fuel pumps in Broncos are notoriously crap. If I had the tank out I think I would change the pump on general principle. Kind of like replacing the clutch when pulling the tranny. If you do not do it you find that you have to drop the tank again in a year and it will probably have 31.5 gallons of gas in it. At least that is how my luck would run.
 

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If it was me I dont think that I could justify $100+ to replace something that is working. If i remember the sending units are around $150
 

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yo,
I hear ya on the $; so save the $ until you need to replace the sender...
http://www.fordparts.com/
Select Model
year, Bronco etc,

Air and Fuel Delivery

Fuel Pumps and Related Components 5.0L - 8Cyl, 4WD 9A299 Fuel Sender (Gas) $186.35


9A407 Fuel Pump and Strainer Set (Fuel Pump And Bracket Asy. - W/O Sender - Tank Unit - Gas); (Incl 4-way micropin connector)


(CG-786) Fuel Pump Mounting Gasket "O" ring - 4 1/4'' OD fuel tank(steel) mounted pump.


for testing and cleaning connector contacts, etc see this by Steve83
http://www.supermotors.net/registry/media/744437


Consider Cut-out Panel Fabrication for Fuel Pump/Level Sender Replacement Section for Links
Source: by various owners in my Site @ http://www.broncolinks.com/index.php?index=616

Get a patch panel from a Bronco or F series @ a yard. or
Patch Panel, 48in. x 16in. for 80-96 Bronco & F Series; $35.00 Source: by Jeff's Bronco Graveyard http://broncograveyard.com/bronco/i-34094-rear-bed-patch-panel-48in-x-16in-.html
 

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Discussion Starter #6
ok thanks a lot for the replies you guys, I have heard of the cut-out panels before. but I think I'm just going to leave the one I'll have. I'm replacing all the old hardware when I put in the new tank, so if my pump goes soon it won't be a huge hassle to just drop the tank again. I don't exactly have the bank to spend right now. Thanks for the advice
 

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yo nashoba171,

I hear ya on the $.

GL!
 

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Thats a very interesting post Steve83. I will have to try this if mine goes bad. I had some pits in my brass float. It looked like if it wasnt leaking now that it will be soon. So I had some redkote that I was lining the old fuel tank with. When I opened the can of redkote I dipped the float in it. Then I hung it up to drip dry. After it dried over night I dipped it again. If anybody is going to use this stuff as a tank liner it needs to be thinned down with acetone before use or it wont cover hardly anything. I used it full strength on the float and it gave it a nice hyde.
 

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Discussion Starter #11
Yeah Steve thats really great thanks for posting it, I'll definitely try that as well if my gauge starts acting up. While I have the sender out I'm definitely going to check the floater for leaks too. That repair seems really simple, maybe I'll even crack open the sender and check the board and wiper arm while I'm at it and clean it...
 

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yo,
As I mentioned in my First reply here;
for testing and cleaning connector contacts, etc see this by Steve83
...
and in my site @ http://www.broncolinks.com/index.php?index=921
for such as;
Description & Operation, Diagnosis & Testing, Removal & Installation, Disassembly & Assembly, Cleaning & Inspection, Specifications & Special Service Tools/Equipment in a 96

Fuel Tank Damage
If fuel indicating system components are functioning properly and inaccurate indications continue, check the fuel tank for damage which may have changed the fuel tank sending unit mounting angle and/or damaged the fuel tank sending unit. Make sure the fuel delivery module (FDM) is the correct model for the vehicle and that the FDM is not contacting the bottom of the fuel tank. Also inspect the vent hoses for kinks or obstructions.
 
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