Conversion of fuel sender unit from XR7 3 pin to Cougar single pin

Cougar Community Classic Cougar Maintenance Restoration and Repair
1

It it easy to convert the (1967) XR7 three pin cable to use the single pin fuel sender unit used on the regular Cougar system. I don’t need the low fuel light. Due to the need to replace the tank urgently I have already installed the available single pin unit. Thanks

2

I would like to buy your old OEM sender.

Before you go to the trouble to do this. Pull then new sender and use an alligator clip lead to hook it up. One lead to ground and one lead to the gauge side of the harness. If you put it on the wrong side don’t worry the low fuel light will light up when the sender is in the full position. Anyway, once you have it hooked up put the key in the accessory position and see if the gauge reads properly. The reproductions are notorious for being off. At least you will know that when it says 3/4 the tank is full… And no you can’t bend the arm to fix it.

I can rebuild and calibrate your OEM sender for $125 and even the low fuel light will work. Or I will buy it for $50 if it is rebuildable.

TO use the single post sender you need to use a ring terminal and a nut on the sender end of a wire and a large bullet terminal on the other end. The housing on the XR7 harness doesn’t let you engage the terminal on the standard sender.

3

Bill -

Along similar lines…my upgraded 69 XR-7 unit I had you restore…can I hook that up to a single line? I must have installed the standard wire loom from dash to trunk - can’t find the green/y wire… Before the upgrade, had standard gage hooked up to yellow and it worked fine on XR-7 console (albeit no low fuel warning). Or do I have to re-install standard gage until I get intermediate wire loom sorted out?

Thanks!

Rod

4

Yes you can. The molded end doesn’t fit but I have seen people cut them down so it can be slipped on the fuel level post on the sender.

You can also use s ring terminal with an extension wire terminated in a large bullet connector

5

Thanks for that info. I was proposing to cut off the current 3 pin connector and put a ring terminal on the correct wire that attaches to the sender. I’m assuming I won’t have to touch the fuel gauge end which is already connected. As long as I can get a basic reading I’ll be happy. Let me know if you think this will be a problem.

6

That would ruin a $70+ harness that is hard to find. The most desired classic car is one that has not been molested… This is sort of the definition of molested, wasting an expensive part to enable the use of an incorrect part. I would not recommend it but it is your car. Keep in mind all you need is a ring terminal, a nut a few inches of wire and a bullet connector.

A better, but still not great, way would be to cut the shroud off the three prong connector and then push the fuel level socket on the stud.

7

Now I get it. I misunderstood the description. You keep the existing connector and extend it by adding a short piece of wire with a suitable ring connection for the single pole terminal and a bullet that fits the existing rubber housing. Thanks a bunch. Sorry I was a bit slow on the uptake :roll_eyes: Les