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  #1  
Old 07-29-2019, 02:04 AM
SVX99 SVX99 is offline
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Join Date: Jun 2018
Location: Brisbane, Queensland, Ausrtalia
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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?
Attached Images
File Type: jpg Intact.jpg (54.2 KB, 30 views)
File Type: jpg Worn contact.jpg (27.3 KB, 28 views)
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  #2  
Old 08-05-2019, 07:59 PM
SVX99 SVX99 is offline
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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).
Attached Images
File Type: jpg Epic Fail.jpg (139.8 KB, 25 views)
File Type: jpg Normal Solder.jpg (72.2 KB, 27 views)
File Type: jpg Repair tests ok.jpg (59.1 KB, 23 views)
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  #3  
Old 08-06-2019, 04:13 AM
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theflystyle theflystyle is offline
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Re: Fuel Sender Unit

Thats great! Did you re-install yet?
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1994 SVX LSi
JDM Tailbar and Grill, Clear Corners, 15min-mod, Nevin Blue RSB, G-FORCE SPORT COMP-2 Tires, Phenolic Spacers (Manifold & Throttle Body), SS Brake Lines, Maniac Electric Motors 160A Alternator
1994 Legacy L
WRX Wheels
2008 Legacy 3.0R
HID, Bilstein F/R, WhiteLine LCA Bushings, Potenza RE970AS PolePosition Tires
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  #4  
Old 08-06-2019, 05:51 AM
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Sean486 Sean486 is offline
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Re: Fuel Sender Unit

Are there not any other newer Subaru fuel senders that can be used?
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1992 SVX LSL 170k [I]4.44 Transmission, Ecutune TCU, Ecutune Stage 1, transmission cooler, silver STI BBS wheels, Sony Bluetooth double DIN head unit, Infinity front speakers, Lamin-X protected headlights
2010 Mazda 6 i Grand Touring - 120K
2007 Honda Odyssey EXL - 100K
2004 Mazda 3 S - 106K
-----------------------------------
1995 SVX Lsi Polo Sold at 118K 2007
2006 Mazda 5 Sold at 60K 2012
2005 Mazda 6i Sport Sold at 206K 2013 great car[/COLOR]
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  #5  
Old 08-08-2019, 11:20 PM
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Sky9pilot Sky9pilot is offline
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Join Date: Dec 2018
Location: WA
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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
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  #6  
Old 08-19-2019, 02:44 AM
SVX99 SVX99 is offline
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Re: Fuel Sender Unit

Yes, all back installed and the fuel gauge works!
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File Type: jpg Working.jpg (59.3 KB, 17 views)
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  #7  
Old 08-19-2019, 04:22 AM
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theflystyle theflystyle is offline
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Re: Fuel Sender Unit

Congrats!

That has to be a great feeling.
__________________
1994 SVX LSi
JDM Tailbar and Grill, Clear Corners, 15min-mod, Nevin Blue RSB, G-FORCE SPORT COMP-2 Tires, Phenolic Spacers (Manifold & Throttle Body), SS Brake Lines, Maniac Electric Motors 160A Alternator
1994 Legacy L
WRX Wheels
2008 Legacy 3.0R
HID, Bilstein F/R, WhiteLine LCA Bushings, Potenza RE970AS PolePosition Tires
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