I recently swapped the sender in my 89 740 turbo with a junk yard donor ('92) to fix the bad fuel lever sensor. I put in a new pump on the sender and replaced the return and supply hoses as the replacement sender had straight pipes coming out of the sender not 90 degree pipes like my original.

Everything seemed good for a while then my main pump became noisy and later died. I replaced it but it was still noisy.

I figured I had a bad sender so I built a test set with a pressure gauge to test some spare tank pumps I had and I would test the installed unit after I removed it. Turns out the amp draw was 2 amps DC with the pumps returning fuel back to my test bucket. With the pumps supplying pressure to a closed gauge it was 3 amps and the PSI was 15.

I then started to remove the sender and saw the supply hose had kinked! The new 180 degree bend was too much. I ended up putting in a 90 elbow and all was well.
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Paul NW Indiana '89 744 Turbo 190 K/ '90 745 turbo 145 K

Hi Spasske,

I fixed my tubular fuel sender unit by spraying carb cleaner inside it then repeatedly turned the unit upside down to check the float able to run to both ends. Good for almost 7 years. Now its becoming stuck again and might need another treatment.

BTW I found out that the IPD oil filter grabber tool (which looks like a big pair of pliers) is good to un-tighten/tighten the fuel tank bung ring. Open to its largest size to grab the ring and turn. No more knocking using screwdriver or wood block.

Regards,
Amarin.

Amarin,

I have a rubber strap wrench that has always worked fine for me.

I sprayed some penetrating fluid inside the original and it seemed to move better but I did not put a lot of effort into it and did not take it apart. Not sure how much got to where. I ended using it in an emergency replacement for my '90 wagon that started leaking at the a return pipe. It seems to get stuck going up to 3/4 which is better than stuck at zero.

I may take apart the float mechanism on the one with the broken pipe when it warms up. I can do an autopsy on it with out worrying about damaging it. Maybe can transplant something off it.
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Paul NW Indiana '89 744 Turbo 190 K/ '90 745 turbo 145 K

The early 850's have a sender encased in an aluminum tube. Somehow, the resistor wires get crudded at the top end. I found that just sliding the float to the top about a dozen times resolves that problem.
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Keeping it running is better than buying new