Fuel Sender Assembly Replacement Utility

Tools Required

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
3. Drain the fuel tank. Refer to Fuel Tank Draining .
4. 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.

5. Remove the fuel sender assembly retaining ring using theJ 44402 Fuel Tank Sending Unit Wrench.
6. Remove the fuel sender assembly and the seal. Discard the seal.

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.

7. Clean the fuel sender sealing surfaces.

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 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 strainer does not block full travel of the float arm.

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

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.

3. Install the fuel sender assembly retaining ring using theJ 44402 Fuel Tank Sending Unit Wrench.
4. Install the fuel tank. Refer to Fuel Tank Replacement .
5. Refill the fuel tank.
6. Tighten the fuel filler cap.
7. Connect the negative battery cable.
8. Inspect for leaks.

8.1.	Turn ON the ignition for 2 seconds.

8.2.	Turn OFF the ignition for 10 seconds.

8.3.	Turn ON the ignition.

8.4.	Inspect for fuel leaks.

Fuel Sender Assembly Replacement Pick-Up

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.

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
3. Remove the pickup box. Refer to Pickup Box Replacement in Body Rear End.
4. Disconnect the fuel sender electrical connectors.
5. Disconnect the fuel sender fuel and evaporative emission (EVAP) pipes.




Important: 

•	The modular fuel sender assembly may spring up from the fuel tank.

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

•	Carefully discard the reservoir fuel into an approved container.

6. While holding the modular fuel sender assembly down, remove the snap ring from designated slots (1) located on the retainer.

1. Install a new O-ring on the modular fuel sender to the tank.
2. Align the tab on front of the modular sender with slot on front of the retainer snap ring.
3. Slowly apply pressure to top of the spring loaded sender until the sender aligns flush with retainer on the tank.

Important: Ensure that the snap ring is fully seated within the tab slots.

4. Insert snap ring into designated slots (1).
5. Connect the fuel sender fuel and EVAP pipes.
6. Connect the fuel sender electrical connectors.
7. Connect the negative battery cable.
8. Inspect for fuel leaks through the following steps:

8.1.	Turn ON the ignition for 2 seconds.

8.2.	Turn OFF the ignition for 10 seconds.

8.3.	Turn ON the ignition.

8.4.	Inspect for fuel leaks.

9. Install the pickup box. Refer to Pickup Box Replacement in Body Rear End.