Gen 1 Toyota Tacoma Wiper Level Float

tl;dr: This is a file for a new wiper level sensor float for a gen 1 Toyota Tacoma. Full step-by-step below.

You will need ASA filament and 2 (2x5mm) magnets.
 

How to fix a broken wiper fluid sensor in a Gen 1 Tacoma

Step 1: Remove the Washer Fluid Reservoir

From under the car disconnect the hose from the washer pump and the connector to the harness. Then you can disconnect the 4 bolts holding it in place. Then from up above you need to lift the tank and push in the two plastic tabs and you can remove the tank from the bottom. 

Step 2: Pull the Sensor

Remove the connecter from the washer pump and then remove the level sensor from the bottom of the tank. Give it a quick clean.

Step 3: Bench Test the Sensor

Start by connecting a multimeter to the two wires coming from the sensor (Red and Black) and set you meter to continuity. Then invert the sensor, when its upside down it should not beep. This lets us know that the issue is the float and not the sensor it self.

 

Step 4: Bench Test the Float
Now to test the float cut a hole in the bottom of a plastic cup the size of the sensor, shove the sensor through it, and filled the cup with water. If it beeps then we know the float is the issue.

Step 5: Open Up the Sensor

There’s a small plastic plug at the top of the sensor holding it together. Clip that off, and the you can now remove the top and the old float. 

Step 6: Drill More Holes in the Top (optional)

With the top off you can see that there are three holes from the factory but also marks for three more. Take a drill and drill out three more small holes.

Step 7: Print a New Float

Using the file provided print a new float. Settings are as follows:

Material: ASA

Walls: 3

Infill: 5%

Layer Height: 0.16

Step 8: Install the Magnets

You also need two small neodymium magnets (5mm x 2mm). Mark the poles and install them in the same orientation. These should just press into place but you can add come super glue to ensure they wont come loose. 

Important: Make sure to test the new float with your multimeter. If the magnet poles are facing the wrong way, the sensor won’t work. You can then mark the top of the new float before you install it.

Step 9: Reassemble the Sensor

Drop the new float into place, put the cap back on, and use a lighter to soften the plastic at the top. Then I press it down a few times with a screwdriver to reseal it.

Step 10: Reinstall and Test

Reinstall the sensor back into the reservoir, reinstalled the reservoir in the truck, fill it up—and enjoy a working washer level sensor and light.