Fuel Sender Assembly Replacement Regular Cab w/26 Gal Tank

Special Tools

J 45722 Fuel Sender Lock Ring Wrench

1. Remove the fuel tank. Refer to Fuel Tank Replacement.
2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service.
3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fittings from the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service.
4. Reposition the fuel and EVAP pipes out of the way.
5. Install the J 45722 (1) to the fuel tank module lock ring.




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.

6. Using the J 45722 and a long breaker bar, rotate the lock ring clockwise unlocking the fuel tank module lock ring.
7. Remove the J 45722 .



8. Remove the fuel tank module lock ring.

Caution: 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.

9. Slowly raise the module until the fuel level sensor float arm is just visible.

Note: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm.

10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank.
11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container.

Note: DO NOT reuse the old fuel tank module O-ring seal.

12. Remove and discard the fuel tank module O-ring seal.




Note: 

•	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.

13. 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.
14. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
15. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.

1. Install a NEW fuel tank module O-ring seal onto the fuel tank.

Note: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm.

2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank.
3. Lower the module assembly into the tank.
4. Position and install the fuel tank module lock ring.



5. Install the J 45722 to the fuel tank module lock ring.

Note: Always replace the fuel tank module seal when installing the fuel tank module. 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.
6. Using the J 45722 and a long breaker bar, rotate the lock ring counterclockwise locking the fuel tank module lock ring.



7. Remove the J 45722 (1) from the fuel tank module lock ring.
8. Position the fuel and EVAP pipes to the module.
9. Connect the fuel tank EVAP pipe quick connect fittings to the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service.
10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service.
11. Install the fuel tank. Refer to Fuel Tank Replacement.

Fuel Sender Assembly Replacement Regular Cab w/34 Gal Tank

Special Tools

J 45722 Fuel Sender Lock Ring Wrench

1. Remove the fuel tank. Refer to Fuel Tank Replacement.
2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service.
3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fitting from the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service.
4. Reposition the fuel and EVAP pipes out of the way.
5. Install the J 45722 (1) to the fuel tank module lock ring.




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.

6. Using the J 45722 and a long breaker bar, rotate the lock ring counterclockwise unlocking the fuel tank module lock ring.
7. Remove the J 45722 .



8. Remove the fuel tank module lock ring.

Caution: 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.

9. Slowly raise the module until the fuel level sensor float arm is just visible.

Note: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm.

10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank.
11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container.

Note: DO NOT reuse the old fuel tank module O-ring seal.

12. Remove and discard the fuel tank module O-ring seal.




Note: 

•	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.

13. 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.
14. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
15. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.

1. Install a NEW fuel tank module O-ring seal onto the fuel tank.

Note: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm.

2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank.
3. Lower the module assembly into the tank.
4. Position and install the fuel tank module lock ring.



5. Install the J 45722 to the fuel tank module lock ring.

Note: Always replace the fuel tank module seal when installing the fuel tank module. 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.
6. Using the J 45722 and a long breaker bar, rotate the lock ring clockwise locking the fuel tank module lock ring.



7. Remove the J 45722 (1) from the fuel tank module lock ring.
8. Position the fuel and EVAP pipes to the module.
9. Connect the fuel tank EVAP pipe quick connect fitting to the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service.
10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service.
11. Install the fuel tank. Refer to Fuel Tank Replacement.

Fuel Sender Assembly Replacement Extended Cab w/26 Gal Tank

Special Tools

J 45722 Fuel Sender Lock Ring Wrench

1. Remove the fuel tank. Refer to Fuel Tank Replacement.
2. Disconnect the fuel tank fuel feed pipe quick connect fitting from the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service.
3. Disconnect the fuel tank evaporative emission (EVAP) pipe quick connect fittings from the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service.
4. Reposition the fuel and EVAP pipes out of the way.
5. Install the J 45722 (1) to the fuel tank module lock ring.




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.

6. Using the J 45722 and a long breaker bar, rotate the lock ring clockwise unlocking the fuel tank module lock ring.
7. Remove the J 45722 .



8. Remove the fuel tank module lock ring.

Caution: 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.

9. Slowly raise the module until the fuel level sensor float arm is just visible.

Note: When removing the module from the fuel tank, be aware that the module reservoir bucket is full of fuel. The module must be tipped slightly during removal to avoid bending the fuel level sensor float arm.

10. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the module from the tank.
11. Carefully discard the fuel in the module reservoir bucket into an approved fuel container.

Note: DO NOT reuse the old fuel tank module O-ring seal.

12. Remove and discard the fuel tank module O-ring seal.




Note: 

•	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.

13. 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.
14. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
15. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.

1. Install a NEW fuel tank module O-ring seal onto the fuel tank.

Note: The bucket must be tipped slightly during installation to avoid bending the fuel level sensor float arm.

2. Tilt the module toward the rear of the fuel tank to allow the fuel level sensor float arm to clear the tank opening. Install the module into the fuel tank.
3. Lower the module assembly into the tank.
4. Position and install the fuel tank module lock ring.



5. Install the J 45722 to the fuel tank module lock ring.

Note: Always replace the fuel tank module seal when installing the fuel tank module. 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.
6. Using the J 45722 and a long breaker bar, rotate the lock ring counterclockwise locking the fuel tank module lock ring.



7. Remove the J 45722 (1) from the fuel tank module lock ring.
8. Position the fuel and EVAP pipes to the module.
9. Connect the fuel tank EVAP pipe quick connect fittings to the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service.
10. Connect the fuel tank fuel feed pipe quick connect fitting to the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service.
11. Install the fuel tank. Refer to Fuel Tank Replacement.