Fuel Sender Assembly Replacement

Fuel Sender Assembly Replacement

Special Tools

J 45722 Fuel Sender Lock Ring Wrench

Removal Procedure




1. Remove the fuel tank. Refer to Fuel Tank Replacement (Pickup) (Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Front) (Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Rear) (Removal and Replacement).
2. Disconnect the fuel lines from the sending unit. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service) or Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).

Caution: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring.

Caution: 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.

Note: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended. Secure the fuel tank in order to prevent fuel tank rotation.

3. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring.




4. Remove the sending unit and seal. Discard the seal.
5. Clean the sending unit sealing surfaces.





Note: Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped.

Note: Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring.

Note: Check the lock ring for flatness.

6. Place the lock ring on a flat surface. Measure the clearance between the lock ring and the flat surface using a feeler gauge at 7 points.
7. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
8. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.

Installation Procedure




1. Install the sending unit and a NEW seal.





Note: Always replace the fuel sender seal when installing the fuel sender assembly. Replace the lock ring if necessary. DO NOT apply any type of lubrication in the seal groove.

Ensure the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction.

2. Use the J 45722 in order to install the fuel sender lock ring. Turn the fuel sender lock ring in a clockwise direction.
3. Connect the fuel lines to the sending unit. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service) or Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
4. Install the fuel tank. Refer to Fuel Tank Replacement (Pickup) (Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Front) (Removal and Replacement)Fuel Tank Replacement (Cab/Chassis - Rear) (Removal and Replacement).