when I get the chance, I'll post pics of the fuel sender that went bad in my 05 SE-OR.
Looking at it closely, I can see what happened - and it will be the same with ALL Pathfinders. Eventually they with ALL have issues. The fuel sender unit has a float that (obviously) floats in the fuel. As the level goes down the arm pivots - at that point where it pivots on the orange body there are some small metal 'fingers'. These very small tabs/fingers make contact with a circuit board and are what 'measures' the remaining fuel. (I'll try to take some close-up pics to show this...then it will make sense).
On my sender unit, these metal fingers had worn almost completely off - they are normally longer and bent so they make good contact with the circuit board (there is a slight bit of play in the pivoting arm and this tension of the fingers holds them to the board).
Well, I fill my tank twice a week and usually run my tank almost dry before filling (get 320miles per tank on average). This constant wear and tear of the metal fingers against the circuit board wore the metal down - I'd estimate about 1/64th of an inch - just enough so that they weren't making contact with the board anymore. I don't know if the gasoline eats at the metal, but the constant rubbing will eventually wear the fingers away - it's almost guaranteed to happen with EVERYONE'S sending unit. I don't know what other manufacturers use for a design, but Nissan's is a POS and is going to keep failing.
My original one failed around 54k miles. I replaced it (ordered from Courtesy Nissan for about $55) around 65k miles (just had to keep an eye on the odometer for 320miles
) and now have 70k miles. I do notice this new sender likes to flash DTE around 240miles, while the old one would wait til about 280miles.
I'll post some pics when I get the chance.....