Fuel sender travels 1/2 way, 1980 280i Stewart warner gauge.

[Tony Trans Am]

Having sorted the fuel tank leak passenger side tank (pig of a job), the next job is the fuel sender, it only seems to travel on the top half of the gauge, resting at the the just under half way point.
Any one else had this issue?

[RCK974X]

Mine stuck completely at about 1/3 full.....and I ran out of gas....

Later at home, I took sender out and found that the little 'pip' on the end of the wiper arm inside the sender had fallen off, and was stuck on one of the burrs. Luckily the wires looked OK.

I carefully filed the arm and replaced pip with a very small nut and bolt, crimped bolt so nut can't fall off, and polished the bolt head so arm slides easily. It still works perfectly !!

Note - I can't remember now, but I think you have to carefully remove the sender's cover (Lucas ones have little tabs, I think the SW was the same...). Inside is a shaped holder wound with resistance wire, and has a wiper arm connected to the float so it moves with fuel level.

The other thing that can happen is that the wire wears out and breaks (seen this on an old Lucas one in a Triumph), and resistance wire won't solder, so then you need a new sender.

[Alpha Omega]

If the fuel sender internal wire is damaged you can repair it
Search Ebay for NiChrome Wire and use it for a re-wind
Here is a very good tutorial - https://www.thesamba.com/vw/forum/viewtopic.php?t=...