Fuel Sender Assembly Replacement 15 Gallon Tank

Tools Required

J39765-A Fuel Sender Lock Ring Tool

1. Remove the fuel tank. Refer to Fuel Tank Replacement .
2. Using the J39765-A , remove the sending unit lock ring.



3. Remove the sending unit and seal. Discard the seal.
4. Clean the sending unit sealing surfaces.

1. Install the sending unit and a NEW seal.
2. Using the J39765-A , install the sending unit lock ring.
3. Install the fuel tank. Refer to Fuel Tank Replacement .

Fuel Sender Assembly Replacement Side Tank

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



2. Remove the 6 nuts (1) and washers (2) from the fuel sender assembly retaining ring.
3. Remove the fuel sender assembly retaining ring (3).
4. Remove the fuel sender assembly (4).

Warning: 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.

5. Remove the fuel sender assembly seal from the fuel tank.

1. Install the fuel sender assembly seal to the fuel tank.

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

2. Care should be taken not to fold over or twist the strainer when installing the sender assembly as this will restrict fuel flow.



3. Install the fuel sender assembly (4) in the fuel tank.
4. Install the fuel sender assembly lock ring (3) to the fuel tank, make sure the lock ring alignment holes fit over the tabs on the tank (8).

Caution: Refer to Fastener Caution in the Preface section.

5. Install the 6 washers (2) and nuts (1) retaining the fuel sender assembly lock ring.

Tighten
Tighten the lock ring nuts to 8 N·m (71 lb in).

6. Install the fuel tank (8). Refer to Fuel Tank Replacement.

Fuel Sender Assembly Replacement Mid Mount Tank

Special Tools

J 44402 Fuel Tank Sending Unit Wrench

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




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.

2. Remove the fuel sender assembly retaining ring using the J 44402 .




Warning: 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

3. Remove the fuel sender assembly and the seal. Discard the seal.
4. Clean the fuel sender sealing surfaces.

Warning: 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.

Note: 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.

1. Install the new seal on the fuel tank.

Caution: Refer to Fastener Caution in the Preface section.




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



3. Install the fuel sender assembly retaining ring using the J 44402 .
4. Install the fuel tank. Refer to Fuel Tank Replacement.

Fuel Sender Assembly Replacement Rear Tank

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



2. Remove the 6 nuts and washers from the fuel sender assembly retaining ring.
3. Remove the fuel sender assembly retaining ring.
4. Remove the fuel sender assembly.

Warning: 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.

5. Remove the fuel sender assembly seal from the fuel tank.

1. Install the fuel sender assembly seal to the fuel tank.

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

2. Care should be taken not to fold over or twist the strainer when installing the sender assembly as this will restrict fuel flow.



3. Install the fuel sender assembly in the fuel tank.
4. Install the fuel sender assembly lock ring to the fuel tank, make sure the lock ring alignment holes fit over the tabs on the tank.

Caution: Refer to Fastener Caution in the Preface section.

5. Install the 6 washers and nuts retaining the fuel sender assembly lock ring.

Tighten
Tighten the lock ring nuts to 11.5 N·m (102 lb in).

6. Install the fuel tank. Refer to Fuel Tank Replacement.