The sender has a very small hole at the bottom in what is otherwise a sealed unit - this is to prevent the sender jumping around when the fuel sloshes about. I suggest you have a look at that hole and perhaps make it a bit bigger? Martin #1458 Walter Coe wrote: > I took a stab at repairing my OEM fuel sender last night. I have discovered > that there are a lot of little things that go wrong inside of these -- > mostly from fuel residues causing bad electrical connections. > > The only problem that I have left is that it took 3 miles worth of driving > for the gauge to make it from empty to full (or should we call that 4/4?) > > Do these floats get less buoyant with age? I don't think it is likely that > I have the sliding contacts on the resistive wire too tight. And I'm sure > the float isn't jamming mechanically because it moved freely while dry. > > Any ideas? > > Walt Tampa, FL