Jonn drove our 1968 MGC Roadster to the fuel station. Upon returning to the workshop, the fuel gauge was only reading half. A test by shorting the wires at the sender showed the gauge reading full, confirming the gauge itself was functional. On reconnecting the sender, the power wire broke.
The wiring was traced from inside the boot, and the rivets in the retaining clip were drilled out to allow access. The damaged section was pulled through, and wire extensions were soldered to both wires. These were tested, shrink-wrapped, and taped. The wires were then pulled back inside the car and connected to the sender. However, the gauge continued to read only half.
To investigate further, the filler neck was removed, and the fuel level was visually confirmed to be nearly full. The fuel was drained, and the sender unit was removed. Inspection revealed a bent lug on the sender that was limiting float movement. This was corrected, and the sender was tested as functional. The sender was refitted and the tank refilled, including an additional top-up. The gauge then read full. The filler neck was reconnected and the boot carpet refitted.
