Fuel Sender Unit
 

I think I have found the problem with my fuel sender not working properly. It has worn contacts.

First photo is from a forum post I read which shows the intact knob at the end of the contact and second photo is my worn one with some "Devil horns" of copper left at the end.

Obvious get a replacement part is hard to do in Australia (only 249 SVXs ever officially sold here).

Normal solder will work but probably won't last as it is soft.

Copper solder would be better but you need a blow torch to melt and that could damage the plastic part.

Any suggestions to fix?

Re: Fuel Sender Unit
 

Well I tried a couple of ways. Made a mold of the good sender unit and tired copper solder but it was an epic fail as everything melted (Copper solder melts at 700C!). Went back to normal solder which worked reasonably well and has tested ok. The Devil's horns are important to hold the solder in place so do not remove them if you find your sender unit has the same wear as mine (which it should).

Re: Fuel Sender Unit
 

Thats great! Did you re-install yet?

Re: Fuel Sender Unit
 

Are there not any other newer Subaru fuel senders that can be used?

Re: Fuel Sender Unit
 

2005 is a long time ago...has there been any new supply of the fuel sending units for the 1996 SVX's since then? I'm needing some repair for my gas guage doesn't always work and sometimes right after a fillup will drop to empty then if I hit some bumps in the road the guage will recycle to full or partly full.
Sky9pilot

Re: Fuel Sender Unit
 

Yes, all back installed and the fuel gauge works!

Re: Fuel Sender Unit
 

Congrats!

That has to be a great feeling.