how to fix the fuel level sender in a w114 - Mercedes-Benz Forum

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post #1 of 25 (permalink) Old 09-12-2013, 07:50 PM Thread Starter
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how to fix the fuel level sender in a w114

The small wires within the level sender are broken causing the level to stay on empty when the tank is full. Where can I get the replacement wire to solder and fix this on the cheap?

Doesn't look too complicated to do. Figure its worth a try for a few dollars considering an new sender is 250ish.
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post #2 of 25 (permalink) Old 09-12-2013, 10:28 PM
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I think the right type of wire is handy to have. I have no idea what that is, although I have messed around with resistance wires, mainly nichrome, some. (I would NOT put the wrong nichrome wire that has full + voltage applied in a fuel tank under ANY circumstances)

You'll need to figure out what the resistance for Full and Empty are (or what the gauge expects to see from the sender in voltage range, and reverse-engineer), then figure out the circumference of the sender that the resistance wire is wrapped around, so you can then figure out how many wraps you need to do to get the right length (and type/resistance) of wire on to the sender so that the gauge reads approximately Full at the top, and approximately empty at the bottom.

More or less.

This might help you out: Resistance Wire.Com | Nickel Chrome, Nickel Copper, and Iron Chrome Aluminum Alloys from Stock

Good luck!

Last edited by Palolo; 09-22-2013 at 09:53 PM. Reason: Caveat
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post #3 of 25 (permalink) Old 09-13-2013, 12:08 PM Thread Starter
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Got some 28 awg copper and some 46 awg nichrome wire on the way to solder in. We will see if it works..

Thanks for the information

Last edited by Shwagondawheels; 09-13-2013 at 12:14 PM.
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post #4 of 25 (permalink) Old 09-14-2013, 07:47 AM
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The wires are nichrome. If you don't have the proper gauge wire, the fuel indicator will not read accurately. However, that may be better than not reading at all...
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post #5 of 25 (permalink) Old 09-14-2013, 08:37 AM Thread Starter
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Originally Posted by LWB250 View Post
The wires are nichrome. If you don't have the proper gauge wire, the fuel indicator will not read accurately. However, that may be better than not reading at all...
I measured them and 46awg nichrome and 28awg copper seems to be what she needs. Its worth a shot at 9 dollars to repair vs. the 335 for a new unit.
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post #6 of 25 (permalink) Old 09-18-2013, 11:43 AM Thread Starter
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Getting no resistance between any of the pins on the level sender top. Any ideas? All the new wires are soldered in but I get no resistance at all just open.
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post #7 of 25 (permalink) Old 09-18-2013, 12:02 PM
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Is there a coating on your wrapped wire? may need to lightly sand to establish electrical path.

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Originally Posted by Shwagondawheels View Post
Getting no resistance between any of the pins on the level sender top. Any ideas? All the new wires are soldered in but I get no resistance at all just open.
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post #8 of 25 (permalink) Old 09-18-2013, 12:31 PM
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Confirm the wires are running in the contacts on the float the correct way..
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post #9 of 25 (permalink) Old 09-18-2013, 12:31 PM Thread Starter
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Is there a coating on your wrapped wire? may need to lightly sand to establish electrical path.
No, this nichorme wire measures open with no resistance. Where can I get the proper wire?
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post #10 of 25 (permalink) Old 09-18-2013, 12:32 PM Thread Starter
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Confirm the wires are running in the contacts on the float the correct way..
They are. The thin wire is wrong
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