Bad fuel sensor in tank - PowerStrokeNation : Ford Powerstroke Diesel Forum
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post #1 of 11 (permalink) Old 05-13-2019, 10:34 PM Thread Starter
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Bad fuel sensor in tank

Got a 1996 Ford F-450 Powerstroke and the front fuel tank is full but the gauge reads empty. We have current going to the tank and when I pulled out the assembly from the tank today heard fuel sloshing around in the float, that was one problem but when I took it to the mechanic to test the electric slide switch (rheostat??) We found that it worked when the float was down and continued showing an increase in electrical data as the float was lifted but when we got to about 2/3 up, it puked out on us dead. It is a bad switch.

I took it into the local Ford dealer and they wanted about $20 for the little metal float barrel but they did not sell the little electrical switch and said I HAD TO BUY THE ENTIRE UNIT.!! WHAT A RIP OFF!!!.. And the price?? WAY north of $200

I refuse to be ripped off by Ford here, You can find all kinds of fuel sending units, complete for all kinds of cars for around $30.

So, any MacGyvers out there to tell me where I could buy just the switch and mount it to where the old switch snaps in?

I realize there will need to be a match up for the current coming from the switch in the cab to the sending unit to get a accurate reading, but if i can just get something close would make me happy. I can drain the diesel out of the float and JB weld the little crack I see where the leak is.

Thanks
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post #2 of 11 (permalink) Old 05-14-2019, 12:44 AM
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Re: Bad fuel sensor in tank

You can have the sender rebuilt.

Somewhere in the forum here in the last 6 months I believe a member posted a link to a shop that rebuilds them.
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96 F250 XLT 4x4, 4:10 gears, 5 speed, Tymar intake and HX hose, downpipe, pyro and boost guages, coolant filter, Luc clutch
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post #3 of 11 (permalink) Old 05-14-2019, 03:47 AM Thread Starter
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Re: Bad fuel sensor in tank

Thanks Bugman I will see what is out there in computerland in the morning..
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post #4 of 11 (permalink) Old 05-14-2019, 04:34 AM
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Re: Bad fuel sensor in tank

It wasn't too far away in a search.

Rebuilt Fuel Sending Unit Specialist
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post #5 of 11 (permalink) Old 05-14-2019, 05:30 AM
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the wholeing sending unit with float is cheap on ebay.
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post #6 of 11 (permalink) Old 05-14-2019, 05:33 AM Thread Starter
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Re: Bad fuel sensor in tank

Thanks again Bugman, I'll give them a call tomorrow. Now I need to find an operating manual for the John Deere 830 tractor I just bought tonight.
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post #7 of 11 (permalink) Old 05-14-2019, 05:36 AM Thread Starter
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Re: Bad fuel sensor in tank

I checked out E-Bay a while back when I knew this was going to be a problem and a lot of sending units but not the one for this truck. i will check them again tomorrow, thanks
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post #8 of 11 (permalink) Old 05-14-2019, 12:20 PM
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Re: Bad fuel sensor in tank

Quote:
Originally Posted by Bugman View Post
It wasn't too far away in a search.

Rebuilt Fuel Sending Unit Specialist
The above company was my post. I have used them before and was satisfied.

I have also bought the float on Summit Racing.
https://www.summitracing.com/parts/sdk-c8zz-9275-c
https://www.summitracing.com/parts/sdk-c0az-9202-b

1996 F350 XL Crew Cab LB 4x4 3:55
Former Ft. Bragg/Pope AFB Truck
DieselSite Coolant Filter
Riff Raff Diesel Turbo & Y Boot Kit
Riff Raff Diesel HPX
Mile Marker 449SS Manual Hubs

1987 F250 XLT Lariat LB 2WD 4:10
6.9/7.3 IDI Swap-SOLD
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2010 John Deere 5055D

1974 Deutz 5506
2950 hours-"The Tank"
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post #9 of 11 (permalink) Old Yesterday, 04:36 AM
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didn't notice the f450 part . I wonder if it's the same front tank as a f350 .
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post #10 of 11 (permalink) Old Yesterday, 01:15 PM
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Re: Bad fuel sensor in tank

Quote:
Originally Posted by 78-79fordman View Post
didn't notice the f450 part . I wonder if it's the same front tank as a f350 .
I am unsure, but was told it was same when I was inquiring on parts and working thru my issues.

1996 F350 XL Crew Cab LB 4x4 3:55
Former Ft. Bragg/Pope AFB Truck
DieselSite Coolant Filter
Riff Raff Diesel Turbo & Y Boot Kit
Riff Raff Diesel HPX
Mile Marker 449SS Manual Hubs

1987 F250 XLT Lariat LB 2WD 4:10
6.9/7.3 IDI Swap-SOLD
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2010 John Deere 5055D

1974 Deutz 5506
2950 hours-"The Tank"
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