finally found what I belive to be the issue with sputtering on my 1990 volvo 740 regina , where the wires go through the top of the sending unit there is no continuity.The new unit is quite costly , does anyone know if there is a way to run new wires through it , safely?

 

It's pretty simple really if indeed it is the wires that are at fault. Remove the entire unit and run new wires to the connectors. Just make certain the connections are tight. Electricity does not ignite gasoline but sparks do. More common as a cause of discontinuity is a failure in the resistance-causing wiring of the sender itself. Upon removing the sender/pump assembly, examine the windings of the resistor wiring where the sender contact rises and falls. Look for a broken winding. You can also ohm the unit at the source, eliminating the wiring from the exam. That should narrow things down for you.

 

I just tore down the sending unit for my '88 744 Turbo and found exactly what you described. A break in the resistance winding where the float contacts rise and fall. The break is right at the base of one of the resistor rods. How do you recommend repairing this, or is repair a lost cause?

 

Hey buddy i have at least 10 sending units available for sale.
they are the 3 wire ones you would find on a bosch dual pump set up.
i personally have the extinct Regina/ bosch hybrid.
Let me know if you need help.
Goldenblock