I extracted the fuel sender thinking that I'd replace a bad pump (symptoms indicated it was not functioning). However, with the unit on my bench, I discovered that the pump works. It appears that there is no continuity between the positive terminal on the pump and the black lead on the outside of the unit. The solder joint just inside of the sender is OK.

I skimmed this excellent tutorial on the 240 sender:

http://cleanflametrap.com/transferPump.htm

The article discusses how cracks in the sheathing at the point of entry into the sender can lead to corrosion. I suspect this happened to me--there is clearly a crack in the black plastic from which the wires protrude.

Is there any hope in pulling it apart and re-soldering, or should I call it a day and order an aftermarket sender unit?

Also, when I extracted the unit from the tank (losing the little ball in the process...but I was able to retrieve), a small magnetic cylinder fell out of the unit onto the floor of the trunk. It is about .5 inches long and 1mm in diameter. I cannot figure out what component it came from. Does anyone know what this could be or whether it is an essential piece? (perhaps a moot point if my sender is bad).


thanks