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7.3L IDI Diesels (Not Power Strokes) Technical discussion of topics related to vehicles powered by the 7.3 Liter In-Direct Injection Navistar engines.

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Old 08-20-2008, 07:18 AM   #1 (permalink)
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fuel sending unit repair kit

Does anyone know where to buy a repair kit for the fuel sending unit. Everythings looks great just needs a new reheostat.7.3 idi.
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Old 08-20-2008, 04:03 PM   #2 (permalink)
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I had both senders fail and looked for parts to repair them about 3 years ago. I could find nothing. Maybe someone else has a place to get parts to rebuild the senders......but I had to get new units from Ford Parts.com.

The other issue is the rubber fuel pickup/screen on the bottom of the senders. They fail/crack/fall off the sender. This will cause you to run out of fuel at roughly 1/4 tank and can suck air into the system. My new senders did this in three months time! I replaced these pieces with a piece of Goodyear fuel line with an inverted "V" or "fishmouth" cut in the bottom of the line so it would not suck on the bottom of the tank. The fuel line is held on my a small hose clamp. This has worked for the last three years.

If I need new senders in the future, I'll replace the fuel pickup/screen on the senders with a lenght of hose BEFORE they go into the tanks.

Just my $0.2

Heath
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Old 08-21-2008, 02:10 PM   #3 (permalink)
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Do the repair as above and use Viton hose . It is too bad that there doesn't seem to be a source for the rheostat part . Consider installing a alternative sending unit from Centroid CENTROID PRODUCTS - Computerized Tank Display - Electronic Senders - capacitive fuel gauges or Isspro ISSPRO.com Your home for quality Gauges, Tachometers, Speedometers, and more! .

I am in the process of try to determine what to order for the the new from tank on my 1994 F250 . (Clearance between the top of tank and the body of the truck , length of probe, resistance (10-180 model is closest to the stock range(15 F-160 E ohms for 1993-1994 model ?) unless e they have a custom model ). I could really use some help here
(length of probe ? ) .

Edit - I called them and they can make one up for the stock sending unit range. Unfortunately I sent the front tank to the scrap yard before measuring the depth . I guess that I will have to wait for the new tank the tank to arrive and measure the depth on it . Then I will order the
sending unit and install the the tank when it arrives .

BTW - link for a Centroid capacitance fuel sending unit installation on a Dodge . -
Fuel Level Sender, Capacitance Type Install Notes - Dodge Diesel - Diesel Truck Resource Forums



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Old 08-21-2008, 03:10 PM   #4 (permalink)
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Thanks for the info on the fuel screen noticed mine missing. no wonder I keep running out of fuel. Had about a 1/4 of a tank when I pulled the sending unit.
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Old 10-21-2008, 04:39 PM   #5 (permalink)
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Quote:
Originally Posted by rkpatt View Post
Do the repair as above and use Viton hose . It is too bad that there doesn't seem to be a source for the rheostat part . Consider installing a alternative sending unit from Centroid CENTROID PRODUCTS - Computerized Tank Display - Electronic Senders - capacitive fuel gauges or Isspro ISSPRO.com Your home for quality Gauges, Tachometers, Speedometers, and more! .

I am in the process of try to determine what to order for the the new from tank on my 1994 F250 . (Clearance between the top of tank and the body of the truck , length of probe, resistance (10-180 model is closest to the stock range(-15 F-160 E ohms for 1993-1994 model ?) unless the they have a custom model ). I could really use some help here .

Thanks

BTW - link for a Centroid capacitance fuel sending unit installation on a Dodge . -
Fuel Level Sender, Capacitance Type Install Notes - Dodge Diesel - Diesel Truck Resource Forums
At ISSPRO we have looked into doing custom senders as an OEM replacement. Does anyone know if the pre-Powerstroke OBS trucks used the same sender as the later OBS trucks? Since I have an OBS, that will probably be one of the earlier ones we develop

It is probably biodiesel which is deteriorating the pickup tubes. We were planning to have you re-use the pickup screen on our kits, but we may have to check them with biodiesel first!

Regards,
Michael Pliska
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Old 10-21-2008, 05:08 PM   #6 (permalink)
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"OBS "? Do you mean old body style like 1984-1997 ? I am pretty sure that the sending units on the later models of the OBS IDI trucks are different . Maybe you can get a rough idea by looking over the Rock Auto and other online catalogs . It seems like that a Ford dealer parts department would have the info you need . As far as the pickup tubes deteriorating , I have seen them broken in tanks that never had biodiesel or WVO in them ( gas and diesel ) . It was just a poor idea on Ford 's part (material ? design ?).


Quote:
Originally Posted by MJPliska View Post
At ISSPRO we have looked into doing custom senders as an OEM replacement. Does anyone know if the pre-Powerstroke OBS trucks used the same sender as the later OBS trucks? Since I have an OBS, that will probably be one of the earlier ones we develop

It is probably biodiesel which is deteriorating the pickup tubes. We were planning to have you re-use the pickup screen on our kits, but we may have to check them with biodiesel first!

Regards,
Michael Pliska
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Old 10-21-2008, 05:26 PM   #7 (permalink)
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Quote:
Originally Posted by rkpatt View Post
"OBS "? Do you mean old body style like 1984-1997 ? I am pretty sure that the sending units on the later models of the OBS IDI trucks are different . Maybe you can get a rough idea by looking over the Rock Auto and other online catalogs . It seem like that a Ford dealer parts department would have the info you need . As far as the pickup tubes deteriorating , I have seen the broken in tanks the never had biodiesel or WVO in them ( gas or diesel ) . It was just a poor idea on Ford 's part .
Yup, I meant Old Body Style. Good idea about using the online catalogs, I'll try looking them up. I bought some for 1997 model year to use for the design, and even bought side and rear tanks for the mock-up. Hopefully they are at least similar to the older OBS designs.

I wonder if the service replacement parts are using different plastic for the pickup tubes? Mine are still going strong in my 1995, with 266k miles.

Regards,
Michael Pliska
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Old 10-21-2008, 07:13 PM   #8 (permalink)
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MJPliska, I too am interested in these "Enhanced" sending units for 3 of my vehicles. I would like them to be adjustable and so that I can set when the "Fuel" light comes on so that I know exactly what is left. My Christmas list is a 3-4 gauges on the pillar for the 88' F350, is this possible?
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Old 10-22-2008, 06:00 PM   #9 (permalink)
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Just out of curiosity, given that I swapped a donor unknown(92/93?) "gasoline tank" in for my rusty diesel tank today and noted a big difference in design for the respective sending units. Are the sender/pump float assemblies interchangeable/interchangeable with modification? If not, why not? While I am on topic, are the front and rear sending units interchangeable given the difference in depth and mounting angles?
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Old 10-23-2008, 06:08 AM   #10 (permalink)
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mstreman - Could you ( or someone else) please give me the measurement of the depth of the front 19 gal tank or the length of the 93 fuel pickup (from lock ring mount to bottom of fuel pickup "sump" area ) . I would also like to have the same information for the rear 18 gallon tank too .





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Old 10-23-2008, 09:46 PM   #11 (permalink)
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RKPAT: I've already reassembled and installed the aft tank, but I have the old one which I had believed was the 19 gal. As to the midship tank, I can only measure the top to bottom assembly as I did not take it apart. I'll try to get you some numbers tomorrow.

As to interchangeability in sending units: gas and diesel sensor/reo/float is the same Part # but the float arm differs on 17 , 18, and 19 gallon aft tanks. When I removed the diesel sender the pickup tube looked like a radar dish with mini dish on the side: each with a screen. The gas version was inside a "white coffee can" with a cushion-like /pad, off centered pickup screen. The midship guts apparently differ only in float arm length/bend. I wonder if the housings and pumps are the same as what I found in the aft tank. I'll soon know as I have a leaky midship tank on my gas F150.

So anyone know how to visually identify the 17gal vs 18gal vs 19 gal without having them side b side? I saw no part numbers stamped on the tanks.

Eman
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Old 10-24-2008, 05:19 AM   #12 (permalink)
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Quote:
When I removed the diesel sender the pickup tube looked like a radar dish with mini dish on the side: each with a screen
I personally think the high rate of pickup breakoff is due to off roading and the fuel sloshing around in the tank when below 1/2 full.

The screen on the base is the first filter, the one on the side is the gelled fuel bypass should the first filter screen get plugged. Pictures I have show a flapper valve only no screen on the bypass.

If your pickup gets broken off or falls off remember there may be some water and crud in the lower 1/4 of the tank so if the sender assy is out consider draining the tank to check.
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Old 10-24-2008, 01:07 PM   #13 (permalink)
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mstrman-

I appreciate your efforts in getting those measurements .

I guess the aft tank in my truck might be a 19 gallon tank . I guess that you just have make a guess from looking at the catalogs .


Auto Parts Fast at RockAuto

Parts Listing - iNeedParts.com


Parts Listing - iNeedParts.com - this tells me it is 18 gal ?
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Old 11-04-2008, 09:49 AM   #14 (permalink)
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Has anyone found a suitable strainer or screen setup that can be attached to the hose for this repair ? I really would like to see something there to keep any stray large particles from being pulled in potential clogging the hose or fouling up the lift pump.

(Possibly along the line of one of these strainers ? -

airless equipment / parts )



- Thanks
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