Fuel Sender Assembly Replacement 4.8L and 5.3L Engines

Tools Required

J 45722 Fuel Sender Lock Ring Wrench

1. Remove the fuel tank. Refer to Fuel Tank Replacement .
2. Disconnect fuel and evaporative emission (EVAP) lines from the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .

Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the 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.

Important: 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.

3. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring.
4. Remove the cam lock ring.



5. Carefully lift the fuel tank module from the fuel tank, enough to access the quick connect fittings below the module cover.
6. Squeeze the quick connect fittings (1) in order to disengage them from the module cover. Refer to Plastic Collar Quick Connect Fitting Service .
7. Remove the fuel tank module from the fuel tank.
8. Remove and discard the fuel tank module seal.




Important: 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.

Important: Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring.

Important: Check the lock ring for flatness.

9. 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.
10. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
11. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.

1. Install the NEW fuel tank module seal onto the fuel tank.
2. Position the fuel tank module part way into the fuel tank.
3. Connect the quick connect fittings (1) to the module cover. Refer to Plastic Collar Quick Connect Fitting Service .
4. Install the fuel tank module into the fuel tank.
5. Place the cam lock ring into position.




Important: Always replace the fuel sender seal when installing the fuel sender assembly. 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. Rotate the cam lock ring clockwise using the J 45722 until fully seated.
7. Connect the fuel and EVAP lines to the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
8. Install the fuel tank. Refer to Fuel Tank Replacement .

Fuel Sender Assembly Replacement 5.3L (L59) Engine

Tools Required

J 45722 Fuel Sender Lock Ring Wrench

1. Remove the fuel tank. Refer to Fuel Tank Replacement .
2. Disconnect the fuel lines from the sending unit, if necessary. Refer to Plastic Collar Quick Connect Fitting Service .
3. Using J 45722 , remove the sending unit lock ring.



4. Remove the lock ring, sending unit, and rubber seal. Discard the seal.
5. Clean the sending unit sealing surfaces.

Important: The fuel pump strainer must be in a horizontal position when the sending unit is installed in the tank. When installing the sending unit, assure that the fuel pump strainer does not block full travel of the float arm.

1. Install the sending unit and a NEW rubber seal.

Align the alignment tab to the correct location on the fuel tank.




2. Using J 45722 , install the sending unit lock ring.
3. Connect the fuel lines to the sending unit, if necessary. Refer to Plastic Collar Quick Connect Fitting Service .
4. Install the fuel tank. Refer to Fuel Tank Replacement .

Fuel Sender Assembly Replacement 6.0L Engine -Dual Tanks - Front

Tools Required

J 45722 Fuel Sender Lock Ring Wrench

1. Remove the front fuel tank. Refer to Fuel Tank Replacement .
2. Disconnect the fuel and evaporative emission (EVAP) lines from the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .




Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the 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.

Important: 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.

3. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring.
4. Remove J 45722 and the lock ring.



5. Carefully lift the fuel tank module from the fuel tank, enough to access the quick connect fitting below the module cover.
6. Disconnect the vapor line quick connect fitting (1) in order to remove the module. Refer to Plastic Collar Quick Connect Fitting Service .
7. Remove the module from the fuel tank.
8. Remove and discard the fuel tank module seal.




Important: 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.

Important: Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring.

Important: Check the lock ring for flatness.

9. 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.
10. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
11. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.

1. Install a NEW fuel tank module seal onto the fuel tank.
2. Position the fuel tank module part way into the fuel tank.
3. Connect the vapor line quick connect fitting (1) to the module. Refer to Plastic Collar Quick Connect Fitting Service .
4. Install the module into the fuel tank.
5. Place the lock ring into position.




Important: Always replace the fuel sender seal when installing the fuel sender assembly. 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 J 45722 , rotate the lock ring clockwise in order to lock the ring.



7. Connect the fuel and EVAP lines to the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
8. Install the front fuel tank. Refer to Fuel Tank Replacement .

Fuel Sender Assembly Replacement 6.0L Engine -Dual Tanks - Rear

Tools Required

J 45722 Fuel Sender Lock Ring Wrench

1. Remove the rear fuel tank. Refer to Fuel Tank Replacement .
2. Disconnect the evaporative emission (EVAP) lines from the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .




Notice: Avoid damaging the lock ring. Use only J-45722 to prevent damage to the 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.

Important: 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.

3. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring.
4. Remove the J 45722 and the lock ring.



5. Carefully lift the fuel tank module from the fuel tank, enough to access the quick connect fittings below the module cover.
6. Disconnect the vapor line quick connect fittings in order to remove the module. Refer to Plastic Collar Quick Connect Fitting Service .
7. Remove the module from the fuel tank.
8. Remove and discard the fuel tank module seal.




Important: 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.

Important: Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW lock ring.

Important: Check the lock ring for flatness.

9. 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.
10. If warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
11. If warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.

1. Install a NEW fuel tank module seal onto the fuel tank.
2. Position the fuel tank module part way into the fuel tank.
3. Connect the vapor line quick connect fittings to the module. Refer to Plastic Collar Quick Connect Fitting Service .
4. Install the module into the fuel tank.
5. Place the lock ring into position.




Important: Always replace the fuel sender seal when installing the fuel sender assembly. 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 J 45722 , rotate the lock ring clockwise in order to lock the ring.



7. Connect the EVAP lines to the fuel tank module. Refer to Plastic Collar Quick Connect Fitting Service .
8. Install the rear fuel tank. Refer to Fuel Tank Replacement .