Tools Required

J 44402 Fuel Tank Sending Unit Wrench

1. Remove the fuel tank. Refer to Fuel Tank Replacement .




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.

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.

Important: 

•	The fuel module assembly may spring up from its position.

•	When removing the fuel module assembly from the fuel tank, be aware that the reservoir bucket is full of fuel. It must be tipped slightly during removal to avoid damage to the float. Discard the fuel module assembly O-ring seal and replace with a new seal.

•	Carefully discard the fuel in the reservoir bucket into an approved container.

•	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.

2. Use the J 44402 to remove the fuel sender assembly retaining ring.




Caution: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container.

3. Disconnect the fuel lines from the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .
4. Remove the fuel sender assembly and the seal. Discard the seal.
5. Clean the fuel sender sealing surfaces.




Important: 

•	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.

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

•	Check the lock ring for flatness.

6. Place the lock ring on a flat surface. Measure the clearance between to lock ring and the flat surface using a feeler gage at 7 different points.

•	If the warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.

•	If the warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.

Caution: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.

1. Install the new seal on the fuel tank.




Important: The fuel pump strainer must be in a horizontal position when the fuel sender is installed in the tank. When installing the fuel sender assembly, assure that the fuel pump strainer does not block full travel of the float arm.

2. Install the fuel sender assembly into the fuel tank.

Notice: Refer to Fastener Notice in the Preface section.





Important: 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.
3. Use the J 44402 to install the fuel sender assembly retaining ring.
4. Connect the fuel lines to the fuel sender assembly. Refer to Fuel Sender Assembly Replacement .
5. Install the fuel tank. Refer to Fuel Tank Replacement .