Fuel Sender Assembly Having Reduced Wear Including Low Wear Resistor Card

The early wear-out of a fuel sender resistor assembly, especially the card and contact components, has been a durability and cost concern, resulting in frequent engineering redesign.

This liquid level sensing device called a fuel sender, has been an expensive and annoying vehicle repair item. Not only do fuel sender designs need to be accurate and durable, designs must be capable of being produced economically. Designs with no moving fuel sender parts are not practical due to cost disadvantages. This paper describes design improvements which address the problems of premature resistor card wear-out in standard fuel sender designs. This paper does not address fuel measurement.