1983 Ranger Fuel Sending Unit Options

[figwig]

I'm working on converting to the Holley Sniper EFI system and I'm trying to take out the fuel sending unit to drill into it and make a fuel return. Problem is, the thing won't come out. It sits directly in the gap between the cab and bed, and so water has fallen on it for 40 years and has caused it to fuse with the tank and locking ring. I've destroyed most of the tabs on the locking ring trying to get it off and wanted to check with you all before i really dig myself into a hole. I was thinking of just cutting through it all and probably destroying the sender just to get it out but i can't find a replacement anywhere. Looks like my options are to retrofit a bronco 2 or 1985 ranger sending unit OR just get a new tank and fuel sender from a different year. Anything i should be wary of with a new tank if i get one from an 85-89? Or does anyone know of other possible solutions?

I know i can probably just drill to the side of the sending unit and place the return but was hoping to remove the sender to clean the tank so it doesn't explode on me. Also wanted to clean the sender because the fuel gauge is always showing 1/4 full - empty.

 

[SenorNoob]

Sounds like an excellent opportunity to swap to a newer tank and sending unit. (Up to 88, then the gauge range changed.)

 

[85_Ranger4x4]

Sounds like an excellent opportunity to swap to a newer tank and sending unit. (Up to 88, then the gauge range changed.)

Then convert to a high pressure in tank pump for the EFI, two birds once stone.

That is what I did for my EFI conversion.

Post in thread 'Aces Killshot Fusion EFI Conversion'

Aug 25, 2026

Reserved

• 85_Ranger4x4

 

[SenorNoob]

I did the same. Though I have longer starting times when below 1/4 tank... It had shown up before that. Really thinking I may need a fuel pressure regulator.

 

[figwig]

I've already got the fuel kit with the external pump and pre and post filters. If i also do the in tank pump i may accidentally cut the carburetor in half with the pressure or maybe the filtration process makes it act as a pseudo regulator. @85_Ranger4x4 Do you have a link to the one you purchased just to save myself the headache of making sure what i get fits an 85-88 tank, if i go that route? Thanks for the replies fellas

 

[85_Ranger4x4]

I've already got the fuel kit with the external pump and pre and post filters. If i also do the in tank pump i may accidentally cut the carburetor in half with the pressure or maybe the filtration process makes it act as a pseudo regulator. @85_Ranger4x4 Do you have a link to the one you purchased just to save myself the headache of making sure what i get fits an 85-88 tank, if i go that route? Thanks for the replies fellas

Precision from O'Reilly for a '86 Ranger, it already has a return line made into it. I swapped in a Kemso 225 pump for a '89 Ranger.

Holley Sniper requires higher pressure than a carb, IIRC around 55psi. That is what my Aces runs also. You can install the pump on the hanger, leave the high pressure pump alone/not power it and pull fuel thru it with a inline pump if you are in limbo and still running a carb until you are ready to plumb in new lines and everything for the high pressure for the fuel injection.

If you replace the hanger assembly with a later one you will need to replace the sender pigtail, you only have two wires and the later pump hanger will have four.

 

[figwig]

Wanted to update on what I did here for anybody else in this position in the future.

I eventually got the fuel sending unit out by continually hitting it with pbblaster and chipping away at the rust with picks for about 2-3 days. After i chipped away a bit, i got vice grips and grabbed the 2 left side tabs and just pulled toward me and saw it move a bit finally. Still couldn't get it to turn fully. I pulled again and bent the lock ring, which created space for me to put a pry bar under it and just break it off. I opened up the unit's float mechanism and saw that the connector strip has broken off the copper arm and i could not figure out the orientation it had to reattach it, i soldered it on for how i thought it worked but the ohm readings were not right so i gave up. After that, I searched high and low for a 1983/1984 fuel sending unit replacement but could not find one. I did find a 1984 bronco 2 unit on LMC trucks that i found doesn't fit right after ordering because its slightly too long. I wasn't able to cancel before they shipped but i had an idea. When i got it, it didn't fit by about an inch, so i got a tube pending tool and slightly bent it little by little until it fit snug. The float's empty sits right above the bottom (maybe too low) but i can't tell if the float at full fit's properly. I think it's at least good enough and helps me avoid spending 200+ on a new tank, sending unit, and plug (with crazy shipping prices). I'll see when i put it all back together, but I feel good about it for now.

One issue though that i haven't dealt with, the fuel level plug does not fit as it is. I may get a new plug or just cut it off, strip the wires and attach it directly. I just need to make sure the connection is solid with it being right next to the fuel.

 

[85_Ranger4x4]

Wanted to update on what I did here for anybody else in this position in the future.

I eventually got the fuel sending unit out by continually hitting it with pbblaster and chipping away at the rust with picks for about 2-3 days. After i chipped away a bit, i got vice grips and grabbed the 2 left side tabs and just pulled toward me and saw it move a bit finally. Still couldn't get it to turn fully. I pulled again and bent the lock ring, which created space for me to put a pry bar under it and just break it off. I opened up the unit's float mechanism and saw that the connector strip has broken off the copper arm and i could not figure out the orientation it had to reattach it, i soldered it on for how i thought it worked but the ohm readings were not right so i gave up. After that, I searched high and low for a 1983/1984 fuel sending unit replacement but could not find one. I did find a 1984 bronco 2 unit on LMC trucks that i found doesn't fit right after ordering because its slightly too long. I wasn't able to cancel before they shipped but i had an idea. When i got it, it didn't fit by about an inch, so i got a tube pending tool and slightly bent it little by little until it fit snug. The float's empty sits right above the bottom (maybe too low) but i can't tell if the float at full fit's properly. I think it's at least good enough and helps me avoid spending 200+ on a new tank, sending unit, and plug (with crazy shipping prices). I'll see when i put it all back together, but I feel good about it for now.

One issue though that i haven't dealt with, the fuel level plug does not fit as it is. I may get a new plug or just cut it off, strip the wires and attach it directly. I just need to make sure the connection is solid with it being right next to the fuel.

You can adjust the float level by bending the float arm.

I highly recommend submitting a tech article on this to help others keep their old beasts alive.

Thread 'How To Post Articles To Be Added To The Site'

Dec 17, 2013

We're always looking for information to share with other enthusiasts.

This is a basic "how to" on submitting information to this site so it can be added to either the:

• 1983-2011 Ford Ranger Tech Library
• 2019+ Ford Ranger Tech Library
• The website in general

If you're not a registered Forum Member, I would encourage you to do so. However, you can still submit information through our Contact Us Page.

Registered Forum Member:

If you're not registered but want to register, you can do so by Registering.

Where To Submit...

• Jim Oaks
• Replies: 1
• Forum: Submit An Article

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