Fuel Tank Unit: Service and Repair

Fuel Sender Assembly Replacement

Tool Required
- J39765-A Fuel Sender Lock Ring Tool.

Removal Procedure

1. Remove the fuel tank.






2. Remove the fuel sender shield fasteners.
3. Remove the fuel sender shield.






4. Disconnect the fuel sender electrical connectors.






Notice: Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints.

5. Disconnect the fuel pipes from the fuel sender.






Important: The fuel sender assembly will spring up when the fuel sender assembly lock ring is removed.

6. Use the J39765-A (1) in order to remove the fuel sender lock ring.

Important: The fuel sender must be tipped in order to remove the sender from the fuel tank. Fuel in the sender reservoir must be placed and stored in an approved container.

7. Remove the fuel sender from the fuel tank.
8. Remove and discard the fuel sender seal.

Installation Procedure

1. Clean the fuel sender sealing flange.

Important: Always replace the fuel sender seal when installing the fuel sender assembly.

2. Install the NEW fuel sender seal to the fuel tank.

Important: Do not fold over or twist the fuel pump strainer when installing the fuel sender assembly, as this will restrict fuel flow. Also, assure that the fuel pump strainer does not block full travel of float arm.

3. Install the fuel sender and the fuel sender lock ring.






4. Use the J39765-A (1) in order to install the fuel sender lock ring.






5. Install the fuel pipes to the fuel sender.






6. Install the fuel sender sensor electrical connectors.






7. Install the fuel sender shield.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

8. Install the fuel sender shield nuts. Tighten the nuts to 6 Nm (53 in. lbs.).
9. Install the fuel tank.