Gas gauge reads empty

[sholzee]

1992 Ford Explorer 4dr 4.0l automatic.Original fuel sending unit tubes rotted out (gas leak), gauge was working fine,bought southern rust free tank and sending unit(one unit assembled). Installed and gas gauge always read empty. Removed "new used" tank and sending unit, found a hole in brass float. Unbolted old float from oringinal sending unit and gauge still reads empty. Hooked float system from southern tank to wiring hareness and moved float by hand, dash gauge responds. Ohmed out wiring hareness from tank in vehicle, full with gas and get 33 ohms. The readings on the original unit are 16 ohms empty 160 ohms full(full up down motion of arm). Could I have another sinking float? can I buy a float only from Ford? I am getting sick of pulling the tank in and out, any cheap ideas? I'm also running out of money.

 

[indianajohn]

The same thing happened to my 91. I found that the sending unit was working properly when operated by hand, but the brass float had a tiny hole/crack which allowed it to fill with gas and sink. I removed the float and drained the gasoline out of it... this will also help you locate the hole since it may be pretty small(you'll have to squeeze the float a few times with the hole pointing downward). Once you have all the gasoline drained out of the float, you can simply soldier the hole up... make sure you let the gas dry first, then apply flux to the brass float where the crack/hole is so the soldier will adhere, then fill the hole with soldier by using a typical handheld soldiering iron. Before putting this back in your tank, you might want to double-check for leaks by submersing it in a glass of water, squeezing it a few times, and checking for bubbles.

I did this procedure to my float, and it has worked perfectly ever since. I'm not familier with the southern sending unit, but it should be similar, (or maybe the original sending unit will fit into the southern tank). I hope this helps.

-jm