Stuck fuel sender
Does anybody know if there is anything attached to the bottom of the fuel sender in the gas tank? I tried to remove the sender but it gets stuck after lifting it 2 or 3 inches. Turning it 90 degrees or so allows it to come out another inch or so, but then it hangs. It feels like it is attached to something inside the tank. I can here a scraping sound from inside as I lift. I don't want to pull too hard, I'm afraid something will break. Tank is full. I was trying to trouble shoot the gauge and believe the problem is with the sending unit. The gauge reads full if I short the ground and purple wire from the sender, but only half full with the wires attached to the sender. Any ideas what could cause it to get stuck???
1985 Euro AT
There's an assembly in the bottom, at least mine a some others but years I don't know. It looks like a little tub with a basket on top. Supposedly it keeps the level from moving around due to sloshing or cornering. Sounds like the sender is caught on that. There's no connection or other hose attached down there.
1980 928S Euro 5 speed
As Glen said, there is a plastic "tub" in the bottom where the sender goes, but the tub has a plastic lid with a hole that the sender goes through. It should slide off as you pull the sender out of the tank, and then just flop around in the tank until you fish it back onto the tub for sender re-installation... I used a long heavy gauge wire with two little hooks bent outward on each end and used it like a pair of tongs to hook the lid in the center hole. Fun. - Ruf
1982 928 "S" Comp. Pkg, Auto, 17" Cup Whls.
Thought this might help you out. Attached is a picture of a 928 sender unit...mine looked exactly like this when I removed in back in July. I superimposed this on the PET parts diagram of the tank so you can see what parts are where.

I'm a little intrigued by the comments from Rufus and Glen, as I do not recall seeing anything floating in my tank after removing the sender (which, by the way, should slip straight out, by my limited experience). Part #11 on the diagram is listed as a "gasket"...not exactly sure if this is what the guys are referring to, but I I believe this is the seal between the top of the sender and the tank. I had a good look in my tank after removing the sender and there was nothing loose or floating in there.

The light brown-colored plastic guard at the bottom of the sender is attached by a nut (IIRC), so it should not be floating around the tank. The working components of the sender are inside the aluminum tube, safe from prying eyes and hands...unless you are the kind of person who like to disassemble things. If you were so inclined, you would see a delicate, but well constructed mechanism, that on my car at least was in perfect condition and working order. There are two independent electric systems for fuel for the gauge and another for the low fuel warning. So even if your fuel gauge is "off", your low fuel warning light should alert you when its time to gas up!

I'm thinking your sender may be hooked on the internal fuel pickup or return line for the tank. With the tank low on fuel, you should be able to see down along the sender and verify what is obstructing it. Take care with this, as you are working with gas...and some delicate parts as well. Use a flashlight and not a shop light...and beware of the gas fumes.

Hope this helps.

SteveCo in St. John's


I've also had the pleasure or removing the sender unit - motivated in part by tracking down a source of gas fumes, the other part being that childish enthusiasm for tearing things apart.
Steve's comments parallel my brief experience on that once and, hopefully, last visit inside a fuel tank. Part #11 is indeed a square flanged neoprene gasket which centers the sending unit in the tank neck, and seals via the 'flange' extending over the tank neck - all held in place by the ~ 4" plastic gland nut.
There's a purpose to this (anal) level of detail that may be related to your issue.
In my '80, for reasons unknown, the top thread on the neck had collapsed inwards for ~ a third of the circumference. The flange on the gasket (#11) was no longer sealing, ergo - gas fumes, generally around the left rear wheel: - admit that it took months to find this!
The sender did not want to come out, bound in place by the top thread! A lot of careful prying, and in the end, a moderated amount of brute force worked. The id of the neck was trimmed back to round with a razor knife, and on reassembly, the unit literally dropped into place. The resealing is another story!
That's the only place I can see your sender binding. As to the sender, as with Steve's exp., it comes out as a single piece with nothing left behind in that crystal clear +60l. of gas looking back at you.
Good luck, G

BTW, that 6-7" piece of return line hose that clamps to the sender - the one that can turn rock hard after a few years of gas fumes!? IF it needs to be replaced (ie., too firm to re-clamp), you can drop the tank and do all the lines (MASOCHIST), or, with a Dremel tool perform a "rear deck-ecktomy" of modest size to get at the forward clamp that can be touched but not turned.
'80 Copper brown 5-sp, Konis/Club sport wheels/S4 wing, 116KKm
'88 Euro, Nougat brown, GTS rear, GT exhaust, 55KKm