After fixing my fuel gauge and filling my tank, I noted that my needle didn't move as I thought it would. I pulled the fuel sender. Externally, it looked fine, but the arm wouldn't move. I opened the top plate to find the inside was coated with white powder (calcium build-up of sorts?).
I scraped as much as I could with a flathead screwdriver, and eventually got the arm to break free, but it's not a smooth movement. I sprayed liquid wrench inside and it moves a little better, but not much. I left some liquid wrench pooled up in there overnight, only to find it's still not moving freely. If I move the arm up (to mimic a full tank) and let go, the arm does not fall down on it's own. I need to shake it a little vigorously for it to fall. I could see case where my gauge reads full, then goes to empty when I hit a large pothole.
Has anyone experienced this before? Any solutions for fixing it? I had thought about putting some CLR in there, but I don't like to mix chemicals (CLR and Liquid Wrench residue?) without knowing if there'd be any adverse reactions.
This is what it looks like after being treated with liquid wrench:
At $100+ for a new one, I'd like to fix this if possible.