I used to work for a major company that made fuel senders. Most are just resistance wire wound around a form and buffed on one side to remove the insulation where the wiper goes.
If the wire is broken, your chances of fixing it are not so good. But if the problem is a build up of varnish on the coil, you might be in luck.
I "repaired" the fuel sender in my 1985 Toyota Corolla by gently cleaning off the accumulated varnish with carb cleaner and a soft toothbrush. Too much carb cleaner and you will dissolve the insulation that separates the wire turns.
If you remove the sender from the tank and measure resistance from the terminal to the chassis you should see a change. There are several standards, but I beleive the Ford senders were Stewart-Warner standard ~40 Ohms at empty and ~240 Ohms at full. The resistance should be between these two values with no dropouts end to end.
By visually inpecting the card and wiper while measuring the resistance, you should be able to isolate the problem quickly. Remember also to check the float.
If you need more help, drop me an email. I would be happy to help you work this out.
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