I don't know what a fuel sending unit looks like brand new, but this one looks like it's broken to me. I have been having PROBLEM (http://67-72chevytrucks.com/vboard/showthread.php?t=214928) after PROBLEM (http://67-72chevytrucks.com/vboard/showthread.php?t=217137) with this d@mn fuel gauge. I did everything I was told to do TWICE and nothing seemed to work. There WAS a rubber washer on the bolt that comes out of the sending unit that the brown wire attached to. That rubber washer was all chewed up, so metal was touching metal and I THINK that was causing the problem. Well, I was preparing to fix that problem when PLUNK - down went the bolt INSIDE the tank :m6: So I pulled the whole unit out and this is what I see:

http://i113.photobucket.com/albums/n210/ultymte/fs3.jpg
http://i113.photobucket.com/albums/n210/ultymte/fs2.jpg
http://i113.photobucket.com/albums/n210/ultymte/fs1.jpg
http://i113.photobucket.com/albums/n210/ultymte/fs4.jpg

It looks to me like that flat copper looking thin piece of metal that points up towards the top of the sending unit is actually broken. For those of you who have seen a new one, should that piece look like that? Somhow I'm thinking it shouldnt and there inlies my problem. Also, where in the he!! do I get one of these from?! :confused:

American Designer corp makes new ones. The Paddock catalogs quite a few, and can help find ones they don't stock. That piece gets kinda expensive, yours MIGHT be repairable. The flat copper piece is a grounding bus for the path to ground for the sending unit. A fabbed "jumper" might fix the unit. Jump from the existing bar to shiney metal (use alligator test leads just to test), if the unit then tests ok, soldering a piece of wire will will make a permanent repair. Be carefull soldering, as that unit will have gasoline residue, and, of course, no soldering around the tank itself.