you can fix your fuel sending unit float by yourself

On my E150 89 5.0 L I had no read on my gauge so I took out my gas tank for further inspection, but before that I checked my gauge by unplugged this one and grond it on the frame to see if the needle got to F position It did. When I pulled out the sending unit I noticed that the float was almost full of gas! Its a brass float It looked that someone before soldered it. I went to the scap yard and look for that float no luck at all. I took one from another ford vehicle its a plastic one flat and long I fit this to the steel arm of my sending unit by bending it so it was a the same level then the other I put everything back in the tank wow it works!!! like my neighbor said float is float it floats thats all. It cost me $2 for the plastic float work 3 hours on the van. Dealer charge $210 for labor and $179 for parts (ole sending unit). I think I'm lucky to fix myself this thing.

You'll be better off in the long term with that plastic float. More and more fuel is getting mixed with alcohols. Alcohols like ethanol, and especially methanol, have an affinity for lead. That includes any solder on floats, and even the lead component alloyed into brass/bronze. The bronze or any soldered joints will eventually dissolve. You probably already found that out the hard way. Commercial methanol distribution systems (such as heat treating atmosphere systems I've worked on) must use all steel or stainless parts, or plastic.

The same thing happens to carburetor floats. Most older carbs that I've worked on in the last several years are getting nothing but plastic replacement floats. Oddly, you can still buy brass. ???

And it's not just the fuel, but many fuel additives like injector cleaners and fuel driers and anti-freezes have alcohols.

Ford was aware of that and was among the first to use plastic lines and fittings for fuel systems. I'm a little surprized your '89 still had brass.

Yes I was surprise too that I had a brass float. I notice at the scrap yard that in the fuel tank they had there, older ones like 88 87 86 had a plastic float, anyway your explanation is very intelligent. Thanks again


Regards!

Denis

A Ford brass float is available at the dealer parts counter new for less than $20-. If the dealer were to make the repairs, yes they would play it safe and replace the whole sending unit. Your savings came your willingness to take the time and accurately diagnos the problem. Good job.