KS Fuel Sender Repair
 

I salvaged an original fuel sender from a '51 Ford, to use in my '46. The float was full of holes and the float rod almost rusted through. Thanks to a Kubes post, I had the knowledge of how to open and check the internals. All was good, and tested okay when connected to the gauge wire at the tank. I had an aftermarket sender that I was going to use, until I found the '51 sender. I used a part of the new arm and new float to repair the KS unit. Just have to install it now.


Looking at the DC aftermarket China sender that I scavenged for pieces, I noticed what looks like a printed circuit board that the resistance wire winding is connected to. Looking closer it is not wire, but metal "printed" on like a circuit board. wonder how long they will last? I know there are lots of posts about how inaccurate these aftermarket senders are, so I'm lucky to have found the KS unit.

Re: KS Fuel Sender Repair
 

You may find that you will have to adjust the little star wheel to fine tune your gauge reading due to different tank sizes of the two vehicles. Turn it CW to move the gauge needle towards FULL and CCW to move it towards EMPTY.

You must have the patience of a toothache when doing this and move star wheel in the tiniest increments humanly possible. It's ok to clamp the tank unit in a vise on the top bulge dia. just below the top. Just don't crush it. I use a 1/4 inch flat blade screw driver.

Also, when you install the float leave it a hair loose so the "spring loop" on the arm isn't squeezing it.

It's sad that the aftermarket sending units are garbage.

Check out the asking price of this KS unit.
https://www.ebay.com/itm/1948-1949-1...MAAOSwe0BeOLlW

Re: KS Fuel Sender Repair
 

19fordy Thank you for the info on adjusting the sender to match the gauge, and about squeezing the float. The price of the KS on eBay is enough for a fellow to go with aftermarket Chinese!

Re: KS Fuel Sender Repair
 

Good job on the referb!

Re: KS Fuel Sender Repair
 

In the process of salvaging this sender, I had created a self inflicted problem and didn't know it. When I connected the sender to test it after I had done the work, the gauge went to FULL. After much poking and thinking, I realized that something didn't look right. I checked a picture I had taken of the inside, and noticed that there was a hole in the arm that shouldn't be. What happened was when I lifted the arm up to clean the contacts I didn't notice that a small piece fell off the arm that sits on the calibrating ramp. That piece is an insulating "button" that keeps the arm isolated from the adjuster. Without this piece, the sender is shorted, causing a FULL reading. No chance on finding the little piece, so I machined a piece out of plastic and inserted it. Compare the two pictures.


Finally got the sender calibrated and installed. Works like new! Thanks again 19Fordy, for the tip on calibrating.

Re: KS Fuel Sender Repair
 

Good job and great post!

Re: KS Fuel Sender Repair
 

Those OEM senders appear on ePay once in a while...at inflated prices but do seem to eventually sell.

Re: KS Fuel Sender Repair
 

51woodie: Thanks for that "button" information.

It looks like you did some soldering on the resistance wire.
If so, please explain why.

Thanks.

Re: KS Fuel Sender Repair
 

Any suggestions on removing rust and corrosion from the unit, looks like it's in good shape other than the corrosion

Jim 1949 F1

Re: KS Fuel Sender Repair
 

I fixed a KS temperature sender a couple of years ago (different, but I believe they work on the same principle). Mine was corroded as well, so I soaked it in Evaporust, which removed the rust and didn't damage anything else.