Special Tools

J 45722 Fuel Sender Lock Ring Wrench

Warning: Refer to Gasoline/Gasoline Vapors Warning in the Preface section.




1. Remove the fuel tank in order to gain access to the secondary fuel tank module (2). Refer to Fuel Tank Replacement.



2. Release the interlock and disconnect the electrical connector (1) from the secondary fuel tank module. Position the connector and wire harness aside.




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

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.

•	Do not allow the tool to come in contact with the fuel pipe while unlocking the cam lock ring.

3. Use the J 45722 Fuel Sender Lock Ring Wrench  (1) and a long breaker-bar (2) in order to unlock the fuel tank module lock ring (3), by turning counterclockwise.
4. Remove the cam lock ring.



5. Partially remove the secondary fuel tank module (2) in order to gain access to the fuel transfer hose quick connect fitting (1). Use care not to damage the float arm (3).
6. Disconnect the fuel transfer hose quick connect fitting (1).
7. Remove the secondary fuel tank module from the fuel tank.
8. Discard the fuel tank module seal (4).




Note: 

•	Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if the lock rings 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.

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

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

1. Install a NEW fuel tank module seal (4).
2. Grasp the fuel transfer hose from inside the fuel tank.
3. Partially install the secondary fuel tank module (2) to the fuel tank.
4. Connect the fuel transfer hose quick connect fitting (1) to the port on the fuel tank module.



5. Press the secondary fuel tank module downward, aligning the module to the encapsulated ring.

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

6. Position the cam lock ring (3) to the fuel tank.

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

7. Use the J 45722 wrench  (1) and a long breaker-bar (2) to install the fuel tank module lock ring (3), by turning clockwise, until fully seated.



8. Connect the electrical connector (1) to the secondary fuel tank module and engage the connector interlock.
9. Install the fuel tank. Refer to Fuel Tank Replacement.