Effects of high eth content on fuel level sensor

Can someone work their magic and get the rest of these thread pages to load? I think littleloogy describes a solution somewhere in the 18 pages:
http://www.mazdaspeedforum.org/forum/f567/e85-remedy-hpfp-hardware-modifications-164812/index18/

 

@VashEXE swapped his gen 2 over to gen 1 basket, including level sensor. Seems like it required some minor modification.
https://mazdaspeeds.org/index.php?threads/gen1-fuel-pump-assembly-in-gen2.3208/

 

I ordered a gen 1 level sensor to compare and see what exactly is different between both gens.

Sent from tapioca

 

Probably the materials in the connector mostly.

 

So far it's been impossible to get a hold of a gen 1 sensor as they're obsolete now. For now I removed the positive terminal and soldered it completely with high lead content solder. I think I'll add a dab of the EZ TURN stuff on the contact pad and a glob over the terminal itself as well.

Sent from tapioca

 

I ended up cutting the terminals off and soldering the wires directly to the board. I went ahead and insulated them with the ez turn stuff. Crossing my fingers here for us gen pu guys. The 1st replacement board I pulled out failed in a similar mode. Purely from the positive terminal.

Sent from tapioca

 

Kind of a shitty way to have to do this but seems likely to survive so long as the solder doesn't lift the traces off the plastic or break loose due to vibration.

 

If it lasts more than 2 weeks, we're getting somewhere lol

 

Welp. It didn't last very long. Dead again.

Sent from tapioca

 

Is there any way to adapt a different fuel level sensor into the housing for your car?

I know there are a ton of Flex Fuel GM vehicles on the road. Maybe an Equinox or Malibu would have a tank in similar size.

 

Did ford ever sell a flex fuel focus? Do the ST guys have this problem?

 

There was mention of a sensor from a 2012 Lincoln MKZ that could be used. I haven't gone down that route yet.

 

It looks like flex fuel was available on certain focus models. Not the ST. Now i'm wondering if i can swap my top hat over to a focus basket.

 

I'm looking at parts on Rock Auto while on the shitter at work

Motorcraft ps603 is for a 2016 flex fuel focus and looks similar to the ms3 assembly. I can't get good enough pictures to confirm but they look really similar

You might have better luck since you have spent a lot of time looking at the stock part

Could always see if it's in stock locally and take your old one in to compare

That era focus is on the same platform as gen 2 so you would think they would be similar

 

I found the 2012 Lincoln MKZ sending unit and it appears to be almost identical to how the stock sensor mounts to the basket.
But this was just a suggestion from littleloogy.
https://www.myautovaluestore.com/motorcraft/ae5z9a299e-mop-ps435

@Easter Bunny heres a photo of the suggested PS603 sensor. It looks like it shares a similar board, but the whole plastic mounting piece is different. https://ford.oempartsonline.com/oem-parts/ford-sender-assembly-fuel-tank-ps603

Now this whole fuel basket assembly may be an option. This is from a 2016 Ford focus SE with flex fuel capability.
https://www.tascaparts.com/oem-part...vPWZvY3VzJnk9MjAxNiZ0PXNlJmU9Mi0wbC1sNC1mbGV4

 

For 84 dollars it's probably worth grabbing the whole basket to compare/cannibalize

Pay attention though I noticed there were different art numbers for flex fuel and non flex fuel cars

 

I just noticed the guide pins are not exactly 180 apart from each other like gen 2 baskets. no go. abort

 

focus st is the same part # so no help there

this volvo part (also same chassis) looks similar, but only one photo

https://www.tascaparts.com/oem-part...vJm89YzMwJnk9MjAxMiZ0PXQ1JmU9Mi01bC1sNS1nYXM=

 

So i have been doing research on the mercury fuel level sensor, and it shares the same part number (AE5Z-9A299-H)
with the following vehicles. Some are flex fuel compatible. I am assuming these specific level sensors should be able to take full e85.

From Tasca:
2012 Ford Fusion SEL 3.0L V6 - Flex
2011 Ford Fusion SEL 3.0L V6 - Flex
2011 Mercury Milan Base, Premier 2.5L L4 - Gas, 3.0L V6 - Flex
2010 Ford Fusion SE, SEL 3.0L V6 - Flex
2010 Mercury Milan Base, Premier 2.5L L4 - Gas, 3.0L V6 - Flex

 

I talked with the lead electrical engineer here at my work. He does all the heavy work on all our power circuit boards. He recalled a time when he repaired fuel level sensors in the avionics industry and suggested completely coating the wires direct to the board with 3M scotchweld 2216. We use this stuff here at work on a daily basis and its basically like jb weld.