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Old 05-14-2018, 12:41 PM   #1
eeaves42
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Question 1996 960 fuel level Fun Times!

Anyone one have any experience with 1996 960 fuel level sensor failures? I have a great working fuel level gauge however the sender is completely wrong. I can't get a new one anywhere.... ipd, FCP, Volvo dealer, Worldpac. No body sells new units. Has anyone try to repair theirs?
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Old 05-14-2018, 12:49 PM   #2
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What is going on with it? I probably have a good used one I will sell.
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Old 05-15-2018, 01:28 PM   #3
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old unit shows 3/8 at all times, then replaced with used level senders from the yard.... one show empty with low gas light on and the other shows 1/4 full. Tank was full at the time.
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Old 05-15-2018, 01:46 PM   #4
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Its part of the fuel pump assembly, right?

Mine has been bad ever since I replaced the fuel pump. The float probably is bound up in there. I think thats what is wrong with mine.
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Old 05-15-2018, 01:50 PM   #5
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You may have knocked the tube loose from the upper half of the sending unit installing it. I see it often with the 7/9 sending units. They are so hard to install through that ridiculous opening in the floor. Another brilliant design from the Volvo designer with a paper bag and crayon.
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Old 05-16-2018, 01:08 AM   #6
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Quote:
Originally Posted by 2manyturbos View Post
You may have knocked the tube loose from the upper half of the sending unit installing it. I see it often with the 7/9 sending units. They are so hard to install through that ridiculous opening in the floor. Another brilliant design from the Volvo designer with a paper bag and crayon.
Yes! Hence the reason I’m not going in there again to fix it!
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Old 05-16-2018, 02:30 AM   #7
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Quote:
Originally Posted by 2manyturbos View Post
You may have knocked the tube loose from the upper half of the sending unit installing it. I see it often with the 7/9 sending units. They are so hard to install through that ridiculous opening in the floor. Another brilliant design from the Volvo designer with a paper bag and crayon.
Beats dropping the tank!
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Old 05-16-2018, 08:48 AM   #8
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[IMG]Fuel Pump[/IMG]
Knocked the tube loose???


It doesn't look like it. The spring loaded tube the float travels in is made up of two tubes that snap together. You may have a contact on the float ghat wore through and has a knife like edge on it that is catching on the wire wrapped resistance rods. I have seen that happen before.

Last edited by 2manyturbos; 05-17-2018 at 09:06 PM..
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Old 05-17-2018, 08:40 PM   #9
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i know they make universal aftermarket ones, but that seems a lot like work. I hope you find a fix. I've been using the odometer since I bought mine lol ~400 miles to a fill up
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