Fuel Sender Assembly Replacement Rear Mounted - 15 Gal

Tools Required

J39765-A Fuel Sender Lock Ring Tool

1. Remove the fuel tank. Refer to Fuel Tank Replacement .
2. Install the J39765-A (1), to the fuel sending unit lock ring.
3. Using the J39765-A and a breaker bar, rotate the J39765-A counterclockwise disengaging the lock ring.
4. Remove the J39765-A , and breaker bar.



5. Remove the sending unit lock ring.
6. Remove and discard the fuel sending unit O-ring seal.

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.

7. Slowly raise the sending unit until the fuel level sensor float arm is just visible.
8. Tilt the module toward the fill tube on the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the sending unit from the tank.

1. Tilt the module toward the fill tube on the fuel tank to allow the level sensor float arm to clear the tank opening. Install the sending unit into the tank.
2. Lower sending unit assembly into the tank.
3. Position a NEW fuel sending unit O-ring seal onto the sending unit.
4. Position the sending unit lock ring onto the sending unit



5. Install the J39765-A (1), to the fuel sending unit lock ring.
6. Using the J39765-A and a breaker bar, rotate the J39765-A clockwise engaging the lock ring.
7. Remove the J39765-A , and breaker bar.
8. Install the fuel tank. Refer to Fuel Tank Replacement .

Fuel Sender Assembly Replacement Mid Mounted

Tools Required

J 44402 Fuel Tank Sending Unit Wrench

1. Remove the fuel tank. Refer to Fuel Tank Replacement .
2. Disengage the fuel tank lock ring retainer (1).



3. Install the J 44402 (1), to the fuel sending unit lock ring.
4. Using the J 44402 and a breaker bar, rotate the J 44402 counterclockwise disengaging the lock ring.
5. Remove the J 44402 , and breaker bar.



6. Remove the sending unit lock ring.

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.

7. Slowly raise the sending unit until the fuel level sensor float arm is just visible.

Important: When removing the sending unit 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.

8. Tilt the module toward the rear of the fuel tank to allow the level sensor float arm to clear the tank opening. Remove the sending unit from the tank.
9. Remove and discard the fuel sending unit seal.

1. Install a NEW fuel sending unit seal to the fuel tank.

Important: 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 level sensor float arm to clear the tank opening. Install the sending unit to the tank.
3. Lower the sending unit into the fuel tank.
4. Position and install the sending unit lock ring.



5. Install the J 44402 (1), to the fuel sending unit lock ring.
6. Using the J 44402 and a breaker bar, rotate the J 44402 clockwise engaging the lock ring.
7. Remove the J 44402 , and breaker bar.



8. Ensure that the fuel tank lock ring retainer (1) is completely engaged to the lock ring.
9. Install the fuel tank. Refer to Fuel Tank Replacement .

Fuel Sender Assembly Replacement Rear Mounted

Fuel Sender Assembly Replacement Side Mounted