never replaced a sending unit in my life
FWIW, unless the thing just rots apart inside the tank, the sending unit is completely repairable. You can fabricate a sweeper if that wears out, although I have never seen one wear out (300K on some cars I've fixed) Even the wire winding can be replaced, just need the proper resistor wire available at any electronics store that carries these kinds of things (not radio shack) Electronics geeks make their own wire-wound power resistors all the time, and that'* all this thing is really... a wire wound resistor.
Also, if the steel lines rust away at the top of the tank, you can buy bulk length tubing, bend it, flare it, (swedge it) - they make the proper tool for putting the correct swedge to fit our GM connectors - and then braize the new pipes in. This is time consuming, but for the cost of your first sender you can get the tools and supplies needed, break even on the first one - then the rest is gravy. Look around your hometowns, you'll find guys selling "rebuilt" units, just add a fuel pump - that'* what these guys are doing, and they're making 100 bucks a sender, doing about 4 a day while crushing beers by the woodstove in the garage after the kids go to bed. This sure beats watching American Idol. There are two guys within a decent driving distance of me, and they offer two prices, one where you keep your old one, one where you give him the old one. Sure, in about 10 minutes to 1 hour, he has yours turned around, on the shelf, ready to go with a price tag of about half the cost of a new one. Just something to think about, with all of you folks here with the same cars and the same issues. Charge the general public 100 bucks a rebuild, charge fellow BCers 50 bucks, everyone wins. Just my 2cents. Mike
1993 Bonneville SE, frame off resto in progress, will be stock except painted black & chrome t-stars, estimated finish date - spring 2009.
Cars in my "fleet": the bonny project, the bonny parts car, 1999 Olds eighty-eight LS anniversary, 2004 chrys T & C.
Husband, father of two daughters, deer hunter and lover of most things GM, (although I do like my Chrysler minivan) - but nothing comes before my girls..
I'd much rather go home after work and be with my family than do anything else..