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holden05 Offline
#1 Posted : Sunday, 11 July 2021 2:52:40 PM(UTC)
holden05

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Hi
Ive replaced the sender/pick up unit, put 20ltrs of fuel in
Where should i expect the fuel guage to read,
The tank was empty and the guage reads just over the red line on the gts dash, does this sound right?
Dr Terry Offline
#2 Posted : Sunday, 11 July 2021 3:23:24 PM(UTC)
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I would expect it to read just over 1/4 tank.

These gauges aren't very accurate or very linear either.

Try different amounts of fuel firstly, don't worry just yet. Also make sure that the engine is running & the gauge is fully warmed up.

The official tank volume for a WB One-Tonner is 70 litres.

You can check the gauge easily by using 3 resistors. Go to Jaycar, 1/4 W resistors are as cheap as chips.

Buy a 10 ohm, an 25 ohm & a 75 ohm.

Disconnect the tank sender wire & put each resistor from the tank wire to earth.

10 ohm should make the gauge read full, the 25 ohm will make it read half & the 75 ohm empty.

If the gauge is OK you can bend the float arm of the sender slightly to make an adjustment.

If the gauge needs attention take it to a good instrument tech.

Part of the gauge is a 5v constant voltage regulator, it may be faulty, that can be checked or repaired at the same time.

The 5v also supplies the temp gauge (& oil if you have one).

Dr Terry

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If at first you don't succeed, just call it Version 1.0
holden05 Offline
#3 Posted : Sunday, 15 August 2021 1:46:08 PM(UTC)
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Ive pulled out new sender and tested it
Tests ok
Ive bend the float arm to be at a similar angle to the old one
Reinstalled sender, after installlation the sender read 33ohm with the roughly 40ltrs of fuel in the tank and that translated to just over 1/4 tank on the guage
I added another 10 litres and now it’s reading 1/2 tank
I guess that’s the as good as it’s gonna get. I least when it says empty I’ll still have a bit to go

Edited by user Sunday, 15 August 2021 7:13:15 PM(UTC)  | Reason: Not specified

Da_Bomb5203 Offline
#4 Posted : Monday, 16 August 2021 6:51:02 PM(UTC)
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HI Guys,

Im a 19yr old with a WB 202. Any suggestions on what might be the steps to troubleshoot a gauge that reads some times and not others. When the tank is full it reads full but as soon as I use about 15L (55L left) it will read empty. Im thinking it might be the sender but I'm not sure. The temp. gauge also kinda works. It reads a normal operating temp. as just below the cold end limit of the scale.

Any help would be appreciated
HK1837 Offline
#5 Posted : Monday, 16 August 2021 7:30:30 PM(UTC)
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Is there a chassis wire going from the 0V (-ve) terminal of the battery to the radiator support, and if it’s there is there contact to the bare metal (no paint underneath)?
Also make sure all the chassis connections in the harness under the dash are in place.
Instruments on these do go haywire if either of these are missing or not connected properly.
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holden05 Offline
#6 Posted : Sunday, 22 August 2021 7:05:59 PM(UTC)
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After adjusting the fuel sender float about as far as I dare and filling the tank up the guage reads 3/4 full . Is there anything I can do to make further adjustments?
Dr Terry Offline
#7 Posted : Monday, 23 August 2021 8:32:26 AM(UTC)
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Originally Posted by: holden05 Go to Quoted Post
After adjusting the fuel sender float about as far as I dare and filling the tank up the guage reads 3/4 full . Is there anything I can do to make further adjustments?


With the tank now full, how many ohms does the sender measure between its connector pin & the main chassis earth. It should be very close to 10 ohms.

If it is around 10 ohms, you have a gauge or wiring or earth issue. If it isn't close to 10 ohms your sender is definitely out of calibration.

Dr Terry
If at first you don't succeed, just call it Version 1.0
holden05 Offline
#8 Posted : Friday, 27 August 2021 8:16:02 PM(UTC)
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I’ll test it on the weekend. When i bent the float arm downwards it got to a point that no matter how much more I bent it the ohms didn’t change, hanging around 33. I left it so the float was level with the pick up sock at empty
holden05 Offline
#9 Posted : Saturday, 28 August 2021 2:07:14 PM(UTC)
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Ive tested the sender now with a full tank and I get 18 ohms in the sender post and a reading of 3/4 on the guage. Any suggestions?
I had tested the sender unit outside the tank and I got 10 ohms full and 73 empty. Any suggestions?
KBM Offline
#10 Posted : Sunday, 29 August 2021 8:06:15 AM(UTC)
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Is there fuel getting into the float?
holden05 Offline
#11 Posted : Sunday, 29 August 2021 12:19:42 PM(UTC)
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Yea i thought that too. There is a mark on the float face but I don’t think it’s a factor. The float looks like a sealed piece
8D11PCH2 Offline
#12 Posted : Monday, 30 August 2021 9:06:11 PM(UTC)
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Best remove the fuel, oil, temp and volt combined gauge assy from the vehicle and have it checked, and repaired if required, by a qualified instrument repairer.
holden05 Offline
#13 Posted : Saturday, 4 September 2021 4:35:48 PM(UTC)
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Ive had the guages tested and they tested ok. So I’m not sure where to go from here
Dr Terry Offline
#14 Posted : Saturday, 4 September 2021 5:24:51 PM(UTC)
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Re-read my post #2 & your post #9. I'm sure your issue is sender calibration.

In your post #9, you say that outside of the tank the sender reads 10 ohms at the full end, but inside the tank it reads 18 ohms when full.

Either the tank is not full or the float is hitting the top of the tank before it gets to its upper limit.

With the sender outside of the tank & properly earthed, does the gauge read full with the sender at maximum swing ?

Dr Terry
If at first you don't succeed, just call it Version 1.0
KBM Offline
#15 Posted : Saturday, 4 September 2021 6:23:07 PM(UTC)
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When the tank was put in was there any reason it could not earth properly? Chassis or tank painted or tared. Check for resistance between sender fitting area and the chassis. should be 0 ohms.
holden05 Offline
#16 Posted : Saturday, 4 September 2021 7:03:39 PM(UTC)
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Ive verified that the tank is indeed full and rechecked the resistance still at approx 17.5 ohms and 3/4 on the guage. Id did however find a 1.5 ohm resistance from the sender body to the tank

Edited by user Saturday, 11 September 2021 2:11:14 PM(UTC)  | Reason: Not specified

holden05 Offline
#17 Posted : Thursday, 16 September 2021 7:50:59 PM(UTC)
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Fixed the ute fuel sender then took her out and did a big ass skid
HK1837 Offline
#18 Posted : Thursday, 16 September 2021 8:07:25 PM(UTC)
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Did your brakes lockup? You didn’t hit anything I hope!
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holden05 Offline
#19 Posted : Thursday, 16 September 2021 10:19:53 PM(UTC)
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Nah mate did brakes before hand
Good to shred some 1990s rubber
HK1837 Offline
#20 Posted : Friday, 17 September 2021 7:18:03 AM(UTC)
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What caused it to skid then?
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If we all had the same (good) taste, who would buy all the Fords?
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