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  • March 28, 2024, 04:08:24 AM

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Author Topic: Fuel Tank Sending unit conversion.  (Read 18751 times)

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Offline Softbuster

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Fuel Tank Sending unit conversion.
« on: March 27, 2011, 06:21:39 PM »
Well last week I took the Fuel tank off of my Eagle wagon, it had a pin-hole leak from rust and the fuel gauge was not working properly.  So I decided to try to repair this.   I took the sending unit apart and found that the contacts inside were messed up, the only time the gauge would read anything was when the tank was completely full, anything less and it would show empty.
So I started looking for a sending unit, but the only ones available are over $100. which is not in my budget for this car.  So I did some research, our eagle sending units read in an ohm range of like 30-248.  Ford uses an ohm range of like 33-240, which would be close enough to work if you can find one that would fit our tanks.

Then I found a sending unit for a universal application in that 33-240 ohm reading, that is able to work with tanks from like 5" to 27" deep.
Its a Sunpro sending unit, part # SUN-CP7583   
which cost me 14.95 +sh from Summit racing , but it could also be found at other places like Jegs racing.

Then I proceeded to modify it to fit onto my old sending unit bracket.

Here is the two side by side.


The new sending unit comes with a diagram to figure out your depth and length of the float arm and stuff.
Pic of the new unit modified to length.


Then I gutted the old sending unit and disassembled the new unit.



Then I mounted the new unit onto the old bracket, I had to drill the hole bigger to fit the new rubber bushing that keeps the sending unit post from grounding to the bracket.  Do this very carefully, you don't want to drill it to big or ruin the old bracket.  You also have to make sure that the float arm does not hit the fuel pickup tube.



throughout this process be Very careful not to ruin the sock on the pickup tube IF you are going to reuse it.

I will hook up the wires and test the unit later this week, it will probably be a while until I get the tank back on the car, I am sandblasting it and fixing a bunch of small pinholes from rust.
But when its done I will let you know how it works and how accurate I think it is.
but in THEORY this should work.

Keith.
1985 Eagle sedan rescue project

Offline IowaEagle

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Re: Fuel Tank Sending unit conversion.
« Reply #1 on: March 27, 2011, 06:34:17 PM »
Keep us up to date on this EGGcellent retrofit.  Once you are done I would like to put it in the AMC Eaglepedia.  Your conversion should be of particular interest to SX/4 and Kammback owners.
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Not a Jeep.  Not a Car.  Its an AMC Eagle!

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Offline thereverendbill

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Re: Fuel Tank Sending unit conversion.
« Reply #2 on: March 27, 2011, 08:09:06 PM »
stoystown auto recyclers offers NEW tanks for our eagles at right around 100 bucks if your interested send me a message and I'll give you their contact info
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1981 Eagle Kammback (restoration in progress)
1983 SX/4 SOLD
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Offline IowaEagle

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Re: Fuel Tank Sending unit conversion.
« Reply #3 on: March 27, 2011, 08:17:22 PM »
Are these the 22 gallon 30 series or the 21 gallon 50 series tanks Bill?
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Not a Jeep.  Not a Car.  Its an AMC Eagle!

1982 Eagle SX/4 Sport;
1980 Concord DL;
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2002 Hyundai Santa Fe;
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Offline shaggimo

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Re: Fuel Tank Sending unit conversion.
« Reply #4 on: March 28, 2011, 08:37:04 AM »
Interesting indeed! Good tips!
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Offline mramc

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Re: Fuel Tank Sending unit conversion.
« Reply #5 on: March 28, 2011, 06:20:27 PM »
Did you think about looking at a Jeep CJ gas tank sender? They look pretty close just looking at them on the internet and run about $53 on the net. LRDaum

Offline eaglefreek

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Re: Fuel Tank Sending unit conversion.
« Reply #6 on: March 28, 2011, 06:27:25 PM »
I used the same sender for my IH Metro. It worked great.
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Offline Draekon

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Re: Fuel Tank Sending unit conversion.
« Reply #7 on: March 28, 2011, 10:47:22 PM »
I believe the resistance is the reverse on that universal gauge.  It reads 33 full while eagles read 30 when empty.  It'll work, just read empty when full and full when empty.
Correct me if I'm wrong though

Offline eaglefreek

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Re: Fuel Tank Sending unit conversion.
« Reply #8 on: March 29, 2011, 09:50:07 PM »
I believe the resistance is the reverse on that universal gauge.  It reads 33 full while eagles read 30 when empty.  It'll work, just read empty when full and full when empty.
Correct me if I'm wrong though
You sure about that? I've never measured one but the info I find while searching says 31 full, 248 empty.
1986 AMC Eagle Wagon 4.2L/4.0L head, AW4,NP242, Chrysler 8.25" rear.
1981 AMC Eagle Wagon As Seen On TV  Lost In Transmission


 

"I know he'd be a poorer man, if he never saw an eagle fly,
Rocky mountain high"  John Denver
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Offline Softbuster

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Re: Fuel Tank Sending unit conversion.
« Reply #9 on: March 29, 2011, 10:14:27 PM »
Then I would have to reverse the wires at the fuel sender, which might work as long as it does not get a ground through the fuel tank  :-\
1985 Eagle sedan rescue project

Offline Draekon

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Re: Fuel Tank Sending unit conversion.
« Reply #10 on: March 30, 2011, 12:51:44 AM »
I believe the resistance is the reverse on that universal gauge.  It reads 33 full while eagles read 30 when empty.  It'll work, just read empty when full and full when empty.
Correct me if I'm wrong though
You sure about that? I've never measured one but the info I find while searching says 31 full, 248 empty.

I'm not sure.  I've just read that eagles and Jeeps are opposite, and from some brief research it looked like the one he ordered is the same direction as Jeeps.

Offline shaggimo

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Re: Fuel Tank Sending unit conversion.
« Reply #11 on: March 30, 2011, 07:27:57 AM »
That depends on the jeep too, some jeeps are opposite of one another. For example, my 87 cherokee had a sender from a 94ish cherokeee in it, the fuel gauge ran backwards, lol.
Even if the replacement did run backwards, I would think one could take it back apart, invert the potentiometer, and rebend the float pole, to trick it into running correct for the eagle....(if that makes sense, lol).
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Offline Softbuster

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Re: Fuel Tank Sending unit conversion.
« Reply #12 on: April 03, 2011, 02:38:22 PM »
I did get a chance yesterday to hook up the wires to test the sender, and it worked fine.
when the float was down it showed empty, and when the float was up it showed full.
Did not have to reverse the wires or change anything.

Now the only question is, how accurate is it when there is fuel in the tank.

it will be a while until I get the tank back on the car, still have fixing to do and not much time to do it.

Keith.
1985 Eagle sedan rescue project

68AMXGOPAC

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Re: Fuel Tank Sending unit conversion.
« Reply #13 on: April 03, 2011, 06:31:45 PM »
Hmmm, I would think it as simple ( not meant sarcastically ) , as measuring the depth of the tank where the sender drops in and moving it up in measurable incriments based on the tank depth.  say - 12" drop - 3" up should be close to a 1/4 , etc etc ., hey as long as empty is empty , that would be my most worry.

Offline thereverendbill

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Re: Fuel Tank Sending unit conversion.
« Reply #14 on: April 03, 2011, 10:24:33 PM »
Are these the 22 gallon 30 series or the 21 gallon 50 series tanks Bill?
22 gallon, i will have to check and see if they offer the 50 series tanks
1980 Eagle 2 door sedan (future solid axle swap)
1981 Eagle Kammback (restoration in progress)
1983 SX/4 SOLD
1983 Eagle Limited wagon  *For Sale* SOLD
1988 Jeep Comanche Pioneer (daily driver)
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Offline BenM

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Re: Fuel Tank Sending unit conversion.
« Reply #15 on: April 03, 2011, 11:03:23 PM »
I've never seen an accurate gas gauge in any car. Full is always some undetermined level above "F" and empty is somewhere around the "E". One car has 5 gallons left, the next stalls when you brake hard.

The incline our tanks have doesn't help anything either in the accuracy department. I'd have to pull out the old calculus book to figure out how to do integrals to measure the actual level in the tank.

My best advice is to try to get it as best you can in range of motion dry, then drive around with a 5-gallon can in the trunk until you're sure how far past "E" empty is. Although, if you keep an eye on your fillups, you can guesstimate where the needle is when you put in 18-20 gallons at a fillup. It may take longer, but you don't risk filling your car in a bad location.
NSS#47184

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Offline Softbuster

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Re: Fuel Tank Sending unit conversion.
« Reply #16 on: April 16, 2011, 10:32:11 PM »
Well I finally got my tank finished today.  So then I went to install the sending unit and ran into a small problem.
It would not fit into the hole in the tank!
I ended up taking the float arm back off, putting it in the tank first, then putting the pickup tube in and reattaching the float arm while it is sticking out of the tank.
I also had to gently squeeze the sending unit arm over a little to get it in the tank.

THEN I had to take it all back apart and do it over because I forgot the O-ring seal!!  :banghead:

But it is now ready to go on the car.

1985 Eagle sedan rescue project

Offline Softbuster

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Re: Fuel Tank Sending unit conversion.
« Reply #17 on: April 23, 2011, 08:33:45 PM »
Today I re installed the gas tank and hooked everything up, and it works well.  It took about three gallons for the gas needle to show above the "E" line.

Word to the wise:  It is easier to put the fuel line on the tank vent before installing the tank.   :P


Whoever is in charge, if you feel like writing up a report and put it on the Eaglepedia, feel free to do so and feel free to use the pictures too.

Keith.
« Last Edit: April 23, 2011, 08:42:11 PM by Softbuster »
1985 Eagle sedan rescue project

Offline Draekon

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Re: Fuel Tank Sending unit conversion.
« Reply #18 on: June 18, 2011, 05:04:04 PM »
This conversion will not work on an SX/4 or Kammback.  The fuel pickup/sending unit is mounted horizontally on the front (or back) of the gas tank.  The aftermarket sending unit would be rotated 90* from where it should be if you tried installing it.  I'm in the process of attempting to find a solution to this, but don't have much faith at this point.

Offline vangremlin

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Re: Fuel Tank Sending unit conversion.
« Reply #19 on: June 18, 2011, 07:55:46 PM »
This conversion will not work on an SX/4 or Kammback.  The fuel pickup/sending unit is mounted horizontally on the front (or back) of the gas tank.  The aftermarket sending unit would be rotated 90* from where it should be if you tried installing it.  I'm in the process of attempting to find a solution to this, but don't have much faith at this point.

New sending units for the SX/4 and Kammback are available from American Parts Depot.  That's where I got mine.
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Offline Draekon

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Re: Fuel Tank Sending unit conversion.
« Reply #20 on: June 18, 2011, 08:06:59 PM »
This conversion will not work on an SX/4 or Kammback.  The fuel pickup/sending unit is mounted horizontally on the front (or back) of the gas tank.  The aftermarket sending unit would be rotated 90* from where it should be if you tried installing it.  I'm in the process of attempting to find a solution to this, but don't have much faith at this point.

New sending units for the SX/4 and Kammback are available from American Parts Depot.  That's where I got mine.

I saw that, but wasn't too thrilled about the $130 price tag.  I was hoping for a cheaper solution.  I may have found a way to mount the universal sending unit, but can't get to the hardware store for bolts right now.

My fuel sock was also fallen apart when I took the assembly out, and it doesn't look like parts stores carry them.

Offline Draekon

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Re: Fuel Tank Sending unit conversion.
« Reply #21 on: June 19, 2011, 06:36:23 PM »
Well I got everything bolted together and was able to fit it into the tank.  I have not completely tested everything yet though, as I am waiting for a new fuel sock (what a :censored: to find).  Here are some pictures to document how I performed this conversion.

Note: This may not be the most effective or easiest way to perform this conversion, but it worked with the limited parts I had available at the time.  Also, the installation was very tight for me, so if anyone replicates this, be careful of how you mount things together.

What the original pickup and sender looked like after pulling it out of the tank.  It was missing both the filter and the float.  Notice that the pickup for the small body eagles is oriented differently than the big body eagles.


The next step was marking the highest, lowest, and middle point of the float.  (I forgot to take a picture until after I gutted the unit, which is why the float arm is missing.)  I also learned that it helps to mark everything with a pen or marker, as you'll be moving the main body, and things tend to get bumped around.


Now it is time to gut the old system.  There are three tabs that need to be bent up, allowing the sending unit to be separated from the case.  You can gut the rest of it.  Once it is gutted, the tabs that originally acted as stops for the float arm can be bent down and are used to mount the new sending unit.  This is how it looks gutted and with the stops bent down:


The hardest part (which lacks pictures the most)  Was modifying the aftermarket sending unit bracket to bolt up to the stock case.  I am kind of glad I didn't take more picture and don't have more steps, because there are probably better ways to do it than I did.
When deciding how high to mount the unit, you just need to get the middle set up right.  The top and bottom are taken care of by how long you cut the float arm.
Here is my finished product:


When installing the unit, some disassembly may be required.  Like softbuster did, I removed the float arm and reattached it after placing it and the pickup in the tank.  I learned later when removing things that this was not necessary in my case.  It is up to you whether you try with or without removing it.
I did, however, have to unscrew the top screw on the bracket, allowing the sending unit to pivot.  After getting everything in the tank, I put the screw back in, realigning it.  Even with doing this, it was a very tight fit to get the pieces in the hole.
« Last Edit: June 19, 2011, 06:40:06 PM by Draekon »

Offline Softbuster

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Re: Fuel Tank Sending unit conversion.
« Reply #22 on: June 19, 2011, 09:43:43 PM »
Cool.

I didn't realize that some eagles had the sending unit mounted horizontally like that.
« Last Edit: June 19, 2011, 09:48:37 PM by Softbuster »
1985 Eagle sedan rescue project

 

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