2.8i fuel sender unit leak from terminal

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80s-new-man
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2.8i fuel sender unit leak from terminal

Post by 80s-new-man »

Hi, second new sender unit bought in 2 years bearing in mind no mileage on the last one in 18 months of lockdown being laid up...and I have petrol leaking again from the terminal insert that has the wire attached.
The last one bought from the club.
Has anyone else had this expensive experience?
Could there just have been a faulty batch of them and just my bad luck?
Cheers
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Re: 2.8i fuel sender unit leak from terminal

Post by Mc Tool »

Not sure about a faulty batch but ....is the terminal riveted thru a plastic block. Some of them have a brass rivet that holds the terminal on the outside and the sender coil on the inside . Sometime a gentle tap on the open end of the rivet will tighten it enough to seal it , or drill the rivet out , re seal the fittings and fit together with brass nut and bolt ( double nut it ). Even if it a metal fitting with sealing washers you can still replace the rivet assuring a tight fit . I did all my headlight fittings .... I think they may have got a blob of solder too. Seems like a lot of shaggin about but after the 2nd dud Id be looking to do the job better myself if I could 😀
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Re: 2.8i fuel sender unit leak from terminal

Post by Bug »

If you need another new one you can widen your search a bit as they are all the same fitting. If you buy one that has both feed and return lines, you can simply use a short bit of pipe, a bolt and a couple of jubilee clips to blank off the output pipe.
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Re: 2.8i fuel sender unit leak from terminal

Post by 80s-new-man »

Thanks guys, it’s one with plastic block, so I’m not sure how to repair... it seems the terminal is embedded in the middle of it and the plastic section is inserted straight into the unit.
To me it looks poorly engineered!
Anyone else bought these recently?
Any other thoughts most welcome!
Cheers
:cheers:
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Re: 2.8i fuel sender unit leak from terminal

Post by mgentry90 »

Yes I had this issue. Caprigear replaced for me
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Re: 2.8i fuel sender unit leak from terminal

Post by Andrew 2.8i »

I've heard of a few people having various issues with the repro fuel senders.
It might be worth sourcing a broken original unit and repairing it. There was a thread on this forum describing how to repair the wound coil part of it.

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Re: 2.8i fuel sender unit leak from terminal

Post by 80s-new-man »

Andy, I always admire your dedication to this forum.
Most appreciated. My mechanic has actually taken the crap thing to bits after discovering a spot weld had created a tiny pin prick , it’s actually not the terminal but one of the spot welds over heating outside tolerances causing a very tiny pin prick of a leak. To me, the CCI SHOULD be responsible for this crap import . However as they would say, oh it’s out of the 12 month warranty, even though she sat there for 18 months not used / fitted because of this virus.
Now my mechanic has decided to repair the pin prick using tank weld over a number of coats. We are hoping it solves it.
The quality does not match price. It’s taking me more than double the price of the item to correct it. That’s not considering the previous guy spent 130 quid on the same brand new club item. They need to look at this.
Cheers
:cheers:
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Re: 2.8i fuel sender unit leak from terminal

Post by D366Y »

80s-new-man wrote: Thu Jun 17, 2021 7:11 pm The quality does not match price. It’s taking me more than double the price of the item to correct it. That’s not considering the previous guy spent 130 quid on the same brand new club item. They need to look at this.
Good luck explaining that to John Hill, I would be most interested to see his response!
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Re: 2.8i fuel sender unit leak from terminal

Post by Bug »

D366Y wrote: Fri Jun 18, 2021 8:38 am
80s-new-man wrote: Thu Jun 17, 2021 7:11 pm The quality does not match price. It’s taking me more than double the price of the item to correct it. That’s not considering the previous guy spent 130 quid on the same brand new club item. They need to look at this.
Good luck explaining that to John Hill, I would be most interested to see his response!
Is he still alive?
If so, has he mastered English yet? :xd:
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Re: 2.8i fuel sender unit leak from terminal

Post by Mc Tool »

Huh , maybe I wont get my screen seal of cci then . I got hold of them years ago re a set of louvers , the guy I spoke ( email )to said " yeah we have them but they are poor quality and you would not be happy with them ". Bumper corners are shite too apparently.
Do they actually make any stuff themselves ,or is it just bought in and on sold ? And , who makes mk3 tail light lenses .🤔😁
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Re: 2.8i fuel sender unit leak from terminal

Post by Andrew 2.8i »

Mc Tool wrote: Fri Jun 18, 2021 8:34 pm Do they actually make any stuff themselves ,or is it just bought in and on sold ?
They don't make anything themselves.
Most stuff they buy in. Those items, like the fuel senders that are the subject of this thread, would be from the same suppliers regardless of who you bought them from.
There are some items that the club commission the manufacturing of. I would guess that the club have more control over the quality of these products.

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Re: 2.8i fuel sender unit leak from terminal

Post by pbar »

Does anyone know please, is it all new fuel senders which suffer from this issue, or just the 2.8 ones?
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Re: 2.8i fuel sender unit leak from terminal

Post by 80s-new-man »

Mc Tool wrote: Fri Jun 18, 2021 8:34 pm Huh , maybe I wont get my screen seal of cci then . I got hold of them years ago re a set of louvers , the guy I spoke ( email )to said " yeah we have them but they are poor quality and you would not be happy with them ". Bumper corners are shite too apparently.
Do they actually make any stuff themselves ,or is it just bought in and on sold ? And , who makes mk3 tail light lenses .🤔😁
The screen seal I got from there was rubbish too. It’s just far too rubbery it’s not firm enough so the sunroof doesn’t work properly, I’ve spent hundreds having it taken to bits and put together again. A complete waste of time and money unfortunately!
Cheers
:cheers:
Capri 2.9i Special 1984 Cossie 24v BOB heart transplant
Sierra XR4x4 2.9i 1992
Jaguar XJR 4.0 SC 2001
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80s-new-man
Posts: 167
Joined: Tue May 21, 2019 11:21 am
Car(s): Ford Capri 2.9 Cosworth Dec 1984, reg. Feb 1985
Ford Sierra XR4x4 2.9 1992
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Location: Suffolk

Re: 2.8i fuel sender unit leak from terminal

Post by 80s-new-man »

:applaud: my mechanic repaired the sender with several layers, over several days, of petrol tank weld.. Found that a weld spat had , in fact burnt an extremely minute pin hole in the inner body. So it wasn’t the terminal, just looked like it…The quality control of these units is practically zero. Crap engineering all made in China, I’m told.
Cheers
:cheers:
Capri 2.9i Special 1984 Cossie 24v BOB heart transplant
Sierra XR4x4 2.9i 1992
Jaguar XJR 4.0 SC 2001
Jaguar F-Type 3.0S sc 380
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