I have a 94 ranger with the 4.0 v6. Could anyone help me out with the dimensions of the Fuel Float Cylinder? Mine is leaking and I've decided to 3d print one, but I don't really want to pull the bed to get the old one out, then pull it again to put new one in.Thanks!

 

Depends on what material you use

It needs to be air tight and have enough buoyancy to lift itself and the metal arm against resistance of the sender

I would think 1" x 3" would be plenty

You can just go to a wrecking yard and get one from pretty much any vehicle, and nylon zap strap it to the arm

Years ago I used 4 ping pong *****, lol

Have you tested OHMs on the Yellow/white stripe wire from the sender?
16ohms empty, 160ohm full is expected

If fuel gauge stays on Empty all the time it is more likely to be the Anti-slosh module on the back side of the instrument cluster than a sender or float issue
This module is a well known failure point on Fords

You can access the Yellow wire back by the gas tank, use a sewing needle to pierce this wire, then test OHMs to Ground, depending on fuel level in the tank it should be between 16-160ohms, if it is then float and sender are OK
If its 16 ohms and there is gas in the tank then sender is OK and float is bad
If ohms are 0 or above 160 then sender is bad,
If 0 ohms then sender or yellow wire is shorted to ground somewhere between gas tank and dash

 

I'm confident it's the float. It has a hole and fills with fuel. I tried to patch it up a while ago because I didn't have time to deal with it, but it failed again. When I unplug the sending unit the guage reads full, since there's no resistance, so everything between the sending unit and the gage works fine.
I designed the new one as a hollow cylinder a 1.25" x2". We'll see what happens.

 

Good testing

That size should be fine

Make sure the material you use is Ethanol friendly/resistant