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I got it all fixed, here is the only pic I took.

Lucky. I thought mine was fixed but it turns out it isn't. Its fine when it is sitting still with no movement but it fills up as soon as the car moves at all. I wonder if I didn't press the brass pin back on tight enough? The old one seemed pretty loose so I put the new one on similarly. Maybe it is too loose and isn't contacting well.

ok, since my instructions seem to be a bit hard to understand, I need to do it on my current car this weekend hopefully, I will try to put together a you-tube video. step by step by step.

No, your writeup was good. I wanted to just replace the contact finger, but my dad insisted that we replace the plug and the whole bit to do it "the right way". So much for that. That is what caused the headache, not your writeup. I really think that I just need to press the contact arm on firmer at this point. I didn't want to overdo it and I think its too loose.

So, what all did you undo?

Because I had to undo everything last night and put the good pieces together.

So, what all did you undo?

Because I had to undo everything last night and put the good pieces together.

Everything has to come back apart again. This will be the third time now.

1/2 way done with mine (camera batteries died) You-tube footage should be uploaded soon

Finished now. It only took about 30-45 mins this time. I just had to tighten up the brass shaft. It works great now. Thanks for the help Hans.

Part 1

http://www.youtube.com/watch?v=-7cY_IPCVfI

Part 2 will be uploaded in a while.

Hans that is awsome work sir!!

I have needed to change mine for about a year now, you have inspired me to go for it. Thanks again you rock!!! Your a star.


Mike

I got around to doing mine this weekend and your post was very helpful thank you very much

Um... so I went to fill up with gas today and once it clicked off (topped off) i heard something spilling under my car. I believe the gasket between the sender and the fuel tank is bad.

Would this be a decent guess?

I never had a problem before, except when I filled up I could smell fuel vapor, but never a spill like this. I lost an approximate amount equal to the size of the filler neck.

I had a same problem after I changed mine. So I took it back apart to see what was going on, and I found that the top fingers where not always making contact with the sensor. I disassembled it and adjusted the finger contacts to ensure that they worked thru the entire motion of the arm. Lastly, I installed everything and tested the gauge before I completely tighten up the retainer ring.

Note: I was also able to test the gauge by its self with the fuel pump relay still removed.

Another Note: while on the bench, looking into the four pin plug you can use an ohm meter to test this as well. The pins I found to show variable resistance where the bottom left and the top right.

I also found that the only way to test it completely is, to take it for a drive around several corners.

Good luck with your repairs.

Mike

I will be installing the fuel sender seal tonight.

The replacement gasket or seal between the sender and tank was $17 plus tax at the local stealership.