Firstfives.org

As many before me have discovered, the fuel gauges in these cars tend to get a little jumpy over time.

I cleaned up the posts of the fuel gauge itself, and also pulled the sender out to check that.

After playing with the sender, it was obvious the fault was with the sender unit. There are two wires that run the length of the sender for the float to tell the gauge where the fuel level is.

Does anyone know of a source for those wires? They are certainly thin, not shielded at all. No idea of gauge, maybe 30 gauge? Just looking for a source to get some of this. Looks easy enough to replace. Solder it to the bottom copper pad, and then pull it tight and solder it to the top connector.

If anyone knows of a source, or even just the type of wire, and size, that would be very helpful

No source I've heard of. I suspect the sending unit is still available since they used it thru the E28 run, but that would be a pretty special wire with a moderate resistance. A contact cleaner might be of help, but doubtful. Double check every ground, they're critical for the fuel and temp gauges.

I was unsure as to what size the wires were, so Initially I bought a 40 gauge Nichrome wire. When it arrived, it looked too thin, but after taking out the sender and looking, they looked very similar.

I checked ohms on the wires that were in place, 41 ohms from end to end. Measured the same length 40 gauge Nichrome, and it ohmed out at 41 ohms.

40 gauge is whats in there, so I replaced the existing wires with new ones. Pulled em tight, soldered in place.

Just gonna watch that gauge, see how it goes.

I'd say you nailed it.

Can you confirm that you used 80/20 nichrome? The resistivity varies by alloy, but 80/20 is the most common. Also, did you use stranded or drawn?

I coaxed new life back in my sender with a thorough cleaning, but remember being shocked at how expensive they are new. With this info I'll have some 40-gauge nichrome in my stores. Thanks!

this was listed as a Nichrome 80 wire, I assume that means 80/20

40 Gauge AWG Nichrome 80 Resistance Wire 100’ Length

And yea, Im with you. Theres not much along the lines to fix in a sender unit, but at $300 or whatever it is they are asking for a new one, well try to fix it up yourself first, sheesh.

Nice fix, my hat's off to you. Where did you find the nichrome wire?

Found it on Amazon

I actually purchased a sampler of Nichrome in various gauges. I think the total was less than $20 shipped