Low Fuel Sending Unit rebuilding service

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xr7g428
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Re: Low Fuel Sending Unit rebuilding service

#11

Post by xr7g428 » 29 Apr 2019, 22:40

I can fix any of them, unless they are rusted out or missing too many parts. No Thermistor will be less money as it is less work. I am thinking $85.
Bill Basore, Editor / Publisher
Legendary Cougar Magazine
Currently in the Cat House
'67 XR7 GT 390 4 speed, AC, AM FM, Lime Frost Green
'68 XR7-G 428CJ C6, Tilt-Away, AM, Black Cherry
'68 XR7-G 390 4 speed, Sunroof, Cardinal Red
'68 XR7 GT-E 427 C6 AM Cardinal Red
'68 XR7 resto mod 351W, soon to be AOD, Black Cherry

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xr7g428
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Re: Low Fuel Sending Unit rebuilding service

#12

Post by xr7g428 » 02 May 2019, 15:39

Before...



And After...



The float on this one was partially turned to lace, eaten completely through by the toxic alcohol water sulfur mix

Bill Basore, Editor / Publisher
Legendary Cougar Magazine
Currently in the Cat House
'67 XR7 GT 390 4 speed, AC, AM FM, Lime Frost Green
'68 XR7-G 428CJ C6, Tilt-Away, AM, Black Cherry
'68 XR7-G 390 4 speed, Sunroof, Cardinal Red
'68 XR7 GT-E 427 C6 AM Cardinal Red
'68 XR7 resto mod 351W, soon to be AOD, Black Cherry

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Blitz
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Re: Low Fuel Sending Unit rebuilding service

#13

Post by Blitz » 02 May 2019, 15:54

If you want to be really fancy... should these be plated or something, to avoid future corrosion? Or is it better to just leave them bare metal?
-Andrew Chenovick
Photo/Video guy for WEST COAST CLASSIC COUGAR, INC.
Side Gig: FLYING A PHOTOGRAPHY


RIDES:
-1968 Mercury Cougar: original family owned, Polar White, 289-2V, auto, AC / "Snowball" view project thread
-1973 Opel Manta: 1.9L, 5-speed (restored)
-1991 Mazda Miata: fun driver
-1992 Volvo 240 wagon: classy hauling machine

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xr7g428
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Re: Low Fuel Sending Unit rebuilding service

#14

Post by xr7g428 » 02 May 2019, 16:13

I think the problem with plating it is that you would really need something that is highly conductive to let the unit ground effectively. But that same highly conductive plating would cause all kinds of problems with all of the electrical connections. Inside the tank the sender is going to get covered with shellac pretty quickly as it gets constantly splashed with gas that dries, and then gets splashed again. Some of the residue I am removing is pretty thick.
Bill Basore, Editor / Publisher
Legendary Cougar Magazine
Currently in the Cat House
'67 XR7 GT 390 4 speed, AC, AM FM, Lime Frost Green
'68 XR7-G 428CJ C6, Tilt-Away, AM, Black Cherry
'68 XR7-G 390 4 speed, Sunroof, Cardinal Red
'68 XR7 GT-E 427 C6 AM Cardinal Red
'68 XR7 resto mod 351W, soon to be AOD, Black Cherry

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Blitz
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Re: Low Fuel Sending Unit rebuilding service

#15

Post by Blitz » 02 May 2019, 16:21

I think you may have just hit on the problem with the new stainless units, I was just talking to Richard about this the other day. He was theorizing that the stainless steel doesn't ground as well. Further testing required to prove this theory...
-Andrew Chenovick
Photo/Video guy for WEST COAST CLASSIC COUGAR, INC.
Side Gig: FLYING A PHOTOGRAPHY


RIDES:
-1968 Mercury Cougar: original family owned, Polar White, 289-2V, auto, AC / "Snowball" view project thread
-1973 Opel Manta: 1.9L, 5-speed (restored)
-1991 Mazda Miata: fun driver
-1992 Volvo 240 wagon: classy hauling machine

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xr7g428
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Re: Low Fuel Sending Unit rebuilding service

#16

Post by xr7g428 » 02 May 2019, 16:49

Let me know what you learn ACP is sending a couple to me to look at.
Bill Basore, Editor / Publisher
Legendary Cougar Magazine
Currently in the Cat House
'67 XR7 GT 390 4 speed, AC, AM FM, Lime Frost Green
'68 XR7-G 428CJ C6, Tilt-Away, AM, Black Cherry
'68 XR7-G 390 4 speed, Sunroof, Cardinal Red
'68 XR7 GT-E 427 C6 AM Cardinal Red
'68 XR7 resto mod 351W, soon to be AOD, Black Cherry

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xr7g428
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Re: Low Fuel Sending Unit rebuilding service

#17

Post by xr7g428 » 11 Jul 2019, 12:35

A heads up... I am getting in senders with pretty severe damage to the float and in some cases the internal sweep arm in the variable resistor box. Even the steel parts are pitted. It tells me that fuel stabilizer is a very good idea if your Cougar is parked most of the time. The float is an easy replacement, but the internal parts are not an easy fix.
Bill Basore, Editor / Publisher
Legendary Cougar Magazine
Currently in the Cat House
'67 XR7 GT 390 4 speed, AC, AM FM, Lime Frost Green
'68 XR7-G 428CJ C6, Tilt-Away, AM, Black Cherry
'68 XR7-G 390 4 speed, Sunroof, Cardinal Red
'68 XR7 GT-E 427 C6 AM Cardinal Red
'68 XR7 resto mod 351W, soon to be AOD, Black Cherry

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R Code
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Re: Low Fuel Sending Unit rebuilding service

#18

Post by R Code » 11 Jul 2019, 14:21

Nice work Bill. If someone sends in one that is too far gone, hit me up, as I have the restored sender from the R Code just sitting here in a box.
- Chris

1967 Std 4 speed conversion
1989 Merkur XR4Ti

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Re: Low Fuel Sending Unit rebuilding service

#19

Post by xr7g428 » 11 Jul 2019, 19:45

It is incredible but these things are specific for each year. The '67 used a smaller feed tube, 5/16", your rubber hose will be too small for a '68. The '68 used the larger 3/8" tube so you will want to stay with that so your rubber fuel line will fit. The '69 has a longer float arm for the larger 20 gallon tank, and they also changed the pin out so it won't connect correctly with '67 or '68. The '70 has an even longer float arm for the larger 22 gallon tank.
Bill Basore, Editor / Publisher
Legendary Cougar Magazine
Currently in the Cat House
'67 XR7 GT 390 4 speed, AC, AM FM, Lime Frost Green
'68 XR7-G 428CJ C6, Tilt-Away, AM, Black Cherry
'68 XR7-G 390 4 speed, Sunroof, Cardinal Red
'68 XR7 GT-E 427 C6 AM Cardinal Red
'68 XR7 resto mod 351W, soon to be AOD, Black Cherry

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Re: Low Fuel Sending Unit rebuilding service

#20

Post by leonbray » 11 Jul 2019, 22:09

xr7g428 wrote:
11 Jul 2019, 19:45
It is incredible but these things are specific for each year. The '67 used a smaller feed tube, 5/16", your rubber hose will be too small for a '68. The '68 used the larger 3/8" tube so you will want to stay with that so your rubber fuel line will fit. The '69 has a longer float arm for the larger 20 gallon tank, and they also changed the pin out so it won't connect correctly with '67 or '68. The '70 has an even longer float arm for the larger 22 gallon tank.
... and the repros all use the same outlet and float arm length
Designed to be driven

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