Tools Required

J 39765 Fuel Sender Lock Nut Wrench

1. Relieve the fuel system pressure. Refer to Plastic Collar Quick Connect Fitting Service .
2. Drain the fuel tank. Refer to Fuel Tank Draining .
3. Remove the fuel tank. Refer to Fuel Tank Replacement .




Notice: In order to prevent damage, cover the fuel pipe fittings with a shop towel before disconnecting the fuel pipes or removal of the fuel sender retaining ring, in order to catch any fuel that may leak out. Place the towel in an approved container when procedure is completed.

4. Disconnect the fuel sender quick-connect fittings. Refer to Plastic Collar Quick Connect Fitting Service .
5. Disconnect the fuel sender electrical connector.
6. Disconnect the fuel tank pressure sensor electrical connector.

Important: The modular fuel sender assembly will spring-up when the locking ring is removed.

7. Use J 39765 to release the lock ring.
8. Remove the lock ring from the fuel sender assembly.

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: When removing the fuel sender assembly from the fuel tank, the reservoir bucket on the fuel sender is full of fuel. The fuel sender must be tipped slightly during removal in order to avoid damage to the float. Place any remaining fuel into an approved container once the fuel sender is removed from the fuel tank.

9. Remove the fuel sender assembly.
10. Clean the fuel sender sealing surfaces.
11. Inspect the fuel sender sealing surfaces.

Important: Care should be taken not to 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 the float arm.

Important: Always replace the fuel sender seal when reinstalling the fuel sender.

1. Position the new fuel sender seal on the fuel tank.
2. Install the fuel sender assembly and the fuel sender lock ring using the J 39765 .
3. Connect the quick-connect fittings at the fuel sender. Refer to Plastic Collar Quick Connect Fitting Service .
4. Connect the fuel sender harness connector.
5. Connect the fuel tank pressure sensor harness connector.
6. Install the fuel tank. Refer to Fuel Tank Replacement .