Fuel Gauge Sender Installation - Land Rovers Only

Den · 08-16-2005, 08:07 AM

I'm attempting to replace the fuel gauge sender unit on my '95 V8 CSW, but after numerous attempts, the float remains fouled on something inside the tank, and the gauge needle remains static on 1/4. Any tips?

TerryS · 08-16-2005, 05:37 PM

I've never done one on a 90, but I'm pretty sure it's the same as on a 110. Once you undo the locking ring, you can withdraw the sender part way, but, then you have to rotate it because of the bends in the sender float rod. There isn't anything for it to hang up on, so you're probabaly not rotating it while withdrawing it.
I guess it goes without saying but you want to do this when you have less than a half tank.

Den · 08-17-2005, 04:25 PM

Thanks TerryS - (Mine's a 1995 110 V8 CSW). OK, I got the sender unit out -the potentiometer contacts were completely worn-out. I connected the new one and checked that the gauge indicates correctly when moving the float lever by hand, which it does.

Now I'm battling to get the new one in! Well, it went in first time, but the gauge didn't move when I filled up. So I pumped most of the fuel back into the front and side reserve fuel tanks, removed the sender unit, verified that it wasn't damaged, and replaced it. And again... And again...! But I can't get it right. I see (with a flashlight) that there are a number of places where the float can get snagged, especially with an empty tank. And when I'm having to do this blind with a few twists before it seats correctly, it appears that chances are slim that I'll ever get it right. And, of course, the float lever may have been inadvertantly bent during the now excessive handling.

I guess I'm heading back to square one!

Den · 08-25-2005, 12:14 PM

Well, as luck would have it (or not), while tinkering around the fuel tank I smelled fuel and noticed a damp strip along the edge of the scrape plate. So now I have removed the entire tank, and the report from the tank repair guy is that it is corroded through under the scrape plate (more about that in a new thread) and I'll need a new one.

On the bright side, I now have the opportunity to see what gives with the sender unit when I install it before fitting the new tank!

That's the end of my thread (and tether).

darkcyde · 06-28-2008, 12:37 AM

I appriciate that this is a very old thread, but I'm having the exact same problem with my Defender 110.

Did you (or anyone else) find out what the problem is? I've tried two different types of sender with different lengths of tube/float arm but the needle still only reads 1/4 of a tank, but it reads a full sweep outside of the tank.

08-16-2005, 08:07 AM	#1 (permalink)
Den Member Join Date: Aug 2005 Location: Johannesburg, South Africa Posts: 41 Gallery: 0	Fuel Gauge Sender Installation I'm attempting to replace the fuel gauge sender unit on my '95 V8 CSW, but after numerous attempts, the float remains fouled on something inside the tank, and the gauge needle remains static on 1/4. Any tips?

08-17-2005, 04:25 PM	#3 (permalink)
Den Member Join Date: Aug 2005 Location: Johannesburg, South Africa Posts: 41 Gallery: 0	It's out, now I can't get the new one in!! Thanks TerryS - (Mine's a 1995 110 V8 CSW). OK, I got the sender unit out -the potentiometer contacts were completely worn-out. I connected the new one and checked that the gauge indicates correctly when moving the float lever by hand, which it does. Now I'm battling to get the new one in! Well, it went in first time, but the gauge didn't move when I filled up. So I pumped most of the fuel back into the front and side reserve fuel tanks, removed the sender unit, verified that it wasn't damaged, and replaced it. And again... And again...! But I can't get it right. I see (with a flashlight) that there are a number of places where the float can get snagged, especially with an empty tank. And when I'm having to do this blind with a few twists before it seats correctly, it appears that chances are slim that I'll ever get it right. And, of course, the float lever may have been inadvertantly bent during the now excessive handling. I guess I'm heading back to square one!

08-25-2005, 12:14 PM	#4 (permalink)
Den Member Join Date: Aug 2005 Location: Johannesburg, South Africa Posts: 41 Gallery: 0	Sender woes continued! Well, as luck would have it (or not), while tinkering around the fuel tank I smelled fuel and noticed a damp strip along the edge of the scrape plate. So now I have removed the entire tank, and the report from the tank repair guy is that it is corroded through under the scrape plate (more about that in a new thread) and I'll need a new one. On the bright side, I now have the opportunity to see what gives with the sender unit when I install it before fitting the new tank! That's the end of my thread (and tether).

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08-16-2005, 05:37 PM	#2 (permalink)
TerryS Moderator Join Date: Aug 2004 Location: Bloomfield, CT If I died today, I lived there all my life. Posts: 2,025 Gallery: 0	I've never done one on a 90, but I'm pretty sure it's the same as on a 110. Once you undo the locking ring, you can withdraw the sender part way, but, then you have to rotate it because of the bends in the sender float rod. There isn't anything for it to hang up on, so you're probabaly not rotating it while withdrawing it. I guess it goes without saying but you want to do this when you have less than a half tank.

06-28-2008, 12:37 AM	#5 (permalink)
darkcyde Member Join Date: Jun 2008 Posts: 1 Gallery: 0	I appriciate that this is a very old thread, but I'm having the exact same problem with my Defender 110. Did you (or anyone else) find out what the problem is? I've tried two different types of sender with different lengths of tube/float arm but the needle still only reads 1/4 of a tank, but it reads a full sweep outside of the tank.

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