Fuel Sender Assembly Replacement Utility

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



3. Remove the fuel sender assembly by using the J 39765 in a counter clockwise motion.

Important: Note the position of the fuel pump strainer.

4. Remove the strainer (2) from the fuel pump.
5. Inspect the fuel pump strainer (2). Replace the strainer if it is contaminated and clean the fuel tank.
6. Disconnect the fuel level sensor electrical connector (7).
7. Remove the fuel level sensor (3) from the sender assembly.
8. Remove the fuel tank pressure sensor (1).

Notice: Do not fold or twist the strainer when installing the sending unit. This action restricts fuel flow.

1. Support the pump with one hand and position the new pump strainer on pump in the same position as noted during disassembly.
2. Push on the outer edge of the ferrule until fully seated.

1. Install the fuel tank pressure sensor (1).
2. Install the fuel level sensor on the sender assembly (3).
3. Connect the fuel level sensor electrical connector (7).
4. Install the fuel pump strainer in its original position (2).
5. Install a new O-ring seal and lock ring.
6. Install the fuel sender assembly.
7. Use the J 39765 to lock the fuel sender assembly retaining ring.
8. Install the fuel tank. Refer to Fuel Tank Replacement .
9. Add fuel removed from the tank.
10. Connect the negative battery cable.
11. Inspect for fuel leaks.

11.1.

Turn the ignition ON for 2 seconds.

11.2.

Turn OFF the ignition for 10 seconds.

11.3.

Again, turn the ignition switch to the ON position.

11.4.

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. Remove the fuel sender assembly by using the J 39765 in a counter clockwise motion.

Important: Note the position of the fuel pump strainer.

5. Remove the strainer (2) from the fuel pump.
6. Inspect the fuel pump strainer (2). Replace the strainer if it is contaminated.
7. Disconnect the fuel level sensor electrical connector (7).
8. Remove the fuel level sensor (3) from the sender assembly.
9. Remove the fuel tank pressure sensor (1).

Notice: Do not fold or twist the strainer when installing the sending unit. This action restricts fuel flow.

1. Support the pump with one hand and position the new pump strainer on pump in the same position as noted during disassembly.
2. Push on the outer edge of the ferrule until fully seated.

1. Install the fuel tank pressure sensor (1).
2. Install the fuel level sensor on the sender assembly (3).
3. Connect the fuel level sensor electrical connector (7).
4. Install the fuel pump strainer in its original position (2).
5. Install a new O-ring seal and lock ring.
6. Install the fuel sender assembly.
7. Use the J 39765 to lock the fuel sender assembly retaining ring.
8. Install the pickup box. Refer to Pickup Box Replacement in Body Rear End.
9. Connect the negative battery cable.
10. Inspect for fuel leaks.

10.1.

Turn the ignition ON for 2 seconds.

10.2.

Turn OFF the ignition for 10 seconds.

10.3.

Again, turn the ignition switch to the ON position.

10.4.

Inspect for fuel leaks.