I am stuck and fed up - help would be appreciated

[kernowman]

I am up and running perfectly at long last - thanks everybody for the help and encouragement, and Duncan for the info on the pump immobiliser. If anybody wants a blow by blow description on dropping the tank and taking out the pump carrier, and how to check that voltage is getting to the pump when it should be, please let me know and I will put it on the forum (sorry, no pics though).
However, do have some pics that might be of interest.

First is the pump carrier and fuel gauge sender unit from inside the tank.
http://www.explorerforum.com/forums/attachment.php?attachmentid=54014&stc=1&d=1239738619
Second shows the two unions that gave me all the trouble mentioned earlier in this post.
http://www.explorerforum.com/forums/attachment.php?attachmentid=54018&stc=1&d=1239739299
Third is the top of the unit - the immobiliser is under the 'tin box' which is spot welded to the unit.
http://www.explorerforum.com/forums/attachment.php?attachmentid=54019&stc=1&d=1239739403
Fourth is the 'tin box' bent up out of the way and showing the join in the pink/black and white/red wires - these were cut off close to the immobiliser. I chose to solder these and sleeve them rather than a crimped connection due to there exposed nature on top of the tank. The 'tin box' was bent back down again to complete the job
http://www.explorerforum.com/forums/attachment.php?attachmentid=54020&stc=1&d=1239739679

Richard

 

[fcat]

Glad you all up and running again! talking of fuel and tanks, is it just me or does everyone elses fuel guage alter nearly as much as 1/4 of a tank depending on whether they are going uphill or downhill ?

 

[kernowman]

Funny you should say that, I noticed that tonight coming home. Don't normally bother much with the fuel gauge as I run most of the time on gas. However, filled up today to half a tank - I live at the top of a very steep hill and coming up tonight it went from half to over three quarters of a tank on the gauge. Also find the last quarter of a tank very unreliable - this seems to be a common problem.

 

[Howard]

The fuel gauge runs front to back in a long thin tank, so gradients will alter the perceived level dramatically. More so the less fuel is in it.