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Westy water tank level sensor repair

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Zeb View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Zeb Quote  Post ReplyReply Direct Link To This Post Topic: Westy water tank level sensor repair
    Posted: 28 Jun 12 at 21:21
Top quality replacement, I Just fitted one of these after repairing my own a couple of times from the earlier post.

I'm not usually in a hurry to chuck out any original parts but it seems to be far more robust than the original.

Great job Holydiver Thanks very much

Zeb


Edited by Zeb - 28 Jun 12 at 21:22
1990 Westfalia California 1.6TD
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Holydiver Quote  Post ReplyReply Direct Link To This Post Posted: 23 Feb 12 at 13:38
Now available if you're interested please PM or email wedgewerks@btinternet.com

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Post Options Post Options   Thanks (0) Thanks(0)   Quote cooky73 Quote  Post ReplyReply Direct Link To This Post Posted: 26 Sep 10 at 20:56
I would but a T4 one if it was cheap - Gunzl wants €130!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Holydiver Quote  Post ReplyReply Direct Link To This Post Posted: 22 Sep 10 at 13:48
Seeing that over 1,300 please have read this post I take it that a lot of you have an issue with your sensor??
 
Since posting this thread I've been thinking about making these, but wonder if there's a market for it??
 
If you think there is PM me and if I get enough I'll look into this again
 
Cheers

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Post Options Post Options   Thanks (0) Thanks(0)   Quote dbeierl Quote  Post ReplyReply Direct Link To This Post Posted: 07 Aug 10 at 04:45
Originally posted by sbbfuk sbbfuk wrote:


It appears to me that these sender units quite commonly fail for 2 main reasons:
a. the plastic rod leaks and takes on water which causes corrosion and deformation of
the copper strip.
b. the magnetic reed switches break (probably because the rods get bent or they are
made to bend due to water getting in and so causing the double sided copper clad
"rod" to bend)
NOTE- these rods are actually VERY fragile, so NEVER try to straighten a bent
one - this is what breaks the glass reed switches!

The leakage failure is mostly because this is a very high-impedance circuit (it's pulled up to +12v through a 1-megohm resistor.  Water soaks into the edges of the PCB and shorts the foils together.  The tipoff for water damage (generally fixable by running several changes of neutral grain spirits through) is that the LED reading may change after the switch has been on for a few minutes.

The breakage failure is purely because the blighters who did the soldering didn't leave any slack in the leads.  Resolder them with a bit of slack and it will stop being so infernally delicate.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Zeb Quote  Post ReplyReply Direct Link To This Post Posted: 07 May 10 at 22:52
Ah I agree that's a little different than replacing the switches. Try Spannerboy on here for a used one then repair if you have to.

Is the pump still in the tank and connected with two spare spade connections for a sensor if you can find one?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote grm2507 Quote  Post ReplyReply Direct Link To This Post Posted: 07 May 10 at 22:23
Yep - I can appreciate that.

My problem was that I had absolutely nothing to work with.  Whoever had the bus before me had taken everything out.

I know I could have got the tube, fixed it to something in the tank lid, got the resistors/reed switches and fixed them to something I could shove into the tube etc. etc...

Not sure I have that much time or inclination.  I'd rather be out using the damn thing!Wink

Mucho respecto for those that do build the things themselves though.
1987 Vanagon GL DJ 2.1 - Dove Blue Metallic

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Zeb View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Zeb Quote  Post ReplyReply Direct Link To This Post Posted: 07 May 10 at 21:48
It really is a simple repair if you have a soldering iron and are able to buy the resistors and reed switches locally. It is much more satisfying to repair/restore the original Westy kit instead of spending loads of cash on aftermarket kit.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote grm2507 Quote  Post ReplyReply Direct Link To This Post Posted: 06 May 10 at 23:39
I bought one of these a while back and never used it (managed to resell on ebay).  It doesn't look that straightforward to fit and certainly isn't a direct replacement for the original sensor.

I managed to get a direct replacement for the original item from BusDepot.com in the US.  A bit pricey but so simple to fit - and worked first time.  Trouble is that I may have got the last one available made by their supplier (I always believe what they tell me!!) - worth checking though.
1987 Vanagon GL DJ 2.1 - Dove Blue Metallic

1991 Westfalia Atlantic JX 1.6TD (Pop-top) - Alpine White
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Post Options Post Options   Thanks (0) Thanks(0)   Quote O===vw===O Quote  Post ReplyReply Direct Link To This Post Posted: 06 May 10 at 23:15
life moves pretty fast,if you dont park the T4 and take a look around once in a while,you could miss it!

03 2.5tdi 88 with decat, egr blank, big injectors, stan intercooler, remap apparently 130bhp
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Holydiver Quote  Post ReplyReply Direct Link To This Post Posted: 02 May 10 at 22:05
Hi Nugget
 
I've got it saved as a word doc PM me your email add and i'll sending to you

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Post Options Post Options   Thanks (0) Thanks(0)   Quote Zeb Quote  Post ReplyReply Direct Link To This Post Posted: 19 Feb 10 at 15:55
I don't think is is there anymore, look at the previous page on this thread as the text has been put here but without the pictures. I don't think you will need anything else.

Cheers

Zeb
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Nugget Quote  Post ReplyReply Direct Link To This Post Posted: 18 Feb 10 at 23:25
Any idea where Lagerheads depth gauge thread can be found? I've done loads of searches on Club 80-90 and clicked the link but can not find anything.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Zeb Quote  Post ReplyReply Direct Link To This Post Posted: 20 Jan 10 at 11:29
OK then please do send me a set if you have them going spare. I checked their site and it is UK delivery only or I need to register and order from the French site, that will be a pain in the arse for me.

I appreciate this and would at least like to give you a couple of pints, so if you have a PayPal account PM me your e-mail address and I'll cover the cost of a couple of beers.

Thanks again

Zeb
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Holydiver Quote  Post ReplyReply Direct Link To This Post Posted: 20 Jan 10 at 08:01
Hi Zeb
 
I still have some here in their bags so took the numbers from them, the photo RS shows on their site is of a SP even for a DP.
The offers still open if you want me to send the set I have.
 
Cheers
G

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Zeb View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Zeb Quote  Post ReplyReply Direct Link To This Post Posted: 19 Jan 10 at 22:43
Thanks, they were the numbers I took from your photo's, I was not sure though as when I looked them up they are both listed as single pole, am I mistaken or is their listing wrong ?

Cheers

Zeb
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Holydiver Quote  Post ReplyReply Direct Link To This Post Posted: 19 Jan 10 at 20:42
Top is SP RS229-3692
Bottom DP RS394-428
 
Smile

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Post Options Post Options   Thanks (0) Thanks(0)   Quote Zeb Quote  Post ReplyReply Direct Link To This Post Posted: 19 Jan 10 at 19:25
Hi sbbfuk

I owe you one already for sending the resistors !

Both part numbers are available from RS but I am not sure which one I need. On the picture in your earlier post you show the packets they came in so I checked the numbers and don't know which to order as they both seem to be single pole switches but a slightly different diameter. I think the picture on their site is a generic one so was no help.

If you can confirm which one I need to order for the upper switch I would be grateful, they both seem to be available and will only cost a couple of pounds. As they are reasonably priced it would be useful if you have a record of the part numbers for both and I will order them just in case I manage to break one when putting the sensor back together.

Cheers

Zeb
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Holydiver Quote  Post ReplyReply Direct Link To This Post Posted: 19 Jan 10 at 08:13
Hi Zeb
 
Glad it helped
I had the same problem on mine I replaced the faulty sw't only to damage the other putting back together as they were so fragile.
 
Top is single pole
Bottom double ploe
 
I do have a spare set if you can't get hold of any.
 
 
Cheers

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Zeb View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Zeb Quote  Post ReplyReply Direct Link To This Post Posted: 18 Jan 10 at 23:21
Hi sbbfuk

The resistors arrived today, thanks very much you have saved me a load of hassle looking for a fault elsewhere in the system. I tried them out and got the correct panel readings instantly.

The level of resistance I was getting when I originally checked the sensor was too low to be correct. This gave me the confidence to dismantle the sensor and have a better look. After scratching my head for a while I discovered the top reed switch connection was burnt (under X10 magnification) it is not disconnecting properly and gives the false reading of full regardless of what the lower reed switch is doing. I can actually hear the lower switch click as the magnet passes over it so it seems to be fine and the contacts also look clean.

So I think all that needs to be done is replacement of the top reed switch.

Looking at the picture in your post I checked RS for the part numbers, I am now confused as both "394-428" and "229-3692" are listed as Single Pole reed switches, which one do I need for the top switch?

Thanks again for your help

Zeb


Edited by Zeb - 18 Jan 10 at 23:32
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