Does anyone know of a way to "electrically" test the fuel level sending unit in the gas tank ? Right now I have the sending unit removed from the tank and I would like to test it to make sure it's working properly before I re-install the tank...After all, it has been setting for over 20 years.

The sending unit is just a variable resistor. In 5th gens the resistance is 0 ohms at empty and 90 ohms at full. I would imagine that the 3rd gens function in a similar manner. Use an ohm meter to check between the wire coming off the sender to the metal of the sender.

The outside of the box on the sending unit on mine does say "90 ohms" but I'm a bit unsure as to where to connect the leads from the meter...I already tried to connect the red lead to the wire coming off the sender and the black lead to the metal box of the sender and I have no movement on the needle of the meter even when I move the float up and/or down ??? :dontknow:

Red to the wire Term.
Black to the Ground Ring - The metal part that will make contact to the Tank.:dontknow:

One meter lead to the terminal where the wire plugs in, one lead to the sender housing.

If it has set for twenty years the wiper is probably not making a connection to the windings. ALA corrosion! If you straighten the tabs around the half moon part it will come apart. You can clean it with tuner cleaner or something similar. It is worth a try - what have you got to loose if you're getting no reading at all through it now.

I think that there is also a ground wire for the sender. Check where the wire connects to the sender. My sender was corroded and after I cleaned it, it worked. I also took apart the resistor and made sure that it was clean. There is not much on a sender to go bad. They just might get dirty.
elamott

Thanks guys...I'm gonna' take it apart in the morning and see what happens !

Struck-Out on the sending unit...I took it all apart and it didn't really seem all that dirty or corroded on the inside, but I cleaned up all the contact points anyway. Put it back together and it's the same thing...no ohm reading whatsoever. Apparently the rheostat/resistor itself on the inside of the box went bad. If you look very closely at mine, you can see where the thin coils of wire are somewhat disrupted or frayed at one spot. Looks like I'm gonna' have to splurge for a new sending unit ! :frown2:

Bought a new sending unit from Advance Auto Parts (one day to get it and only $50.99) :nanawrench:...Also got the shipment from NPD with new hose, clamps, & tank mounting fastener kit...Unfortunately, "anti-squeak pads" are still on Backorder ! :cry:

http://i34.tinypic.com/dz9o4h.jpg