Tools Required

J 39765 Fuel Sender Lock Ring Wrench

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



2. Disconnect the fuel sender module electrical connectors (1).

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.

3. Disconnect the fuel pipes (2) from the fuel sender. Refer to Plastic Collar Quick Connect Fitting Service .




Notice: Avoid damaging the lock ring. Use only the J-39765 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.

4. Use the J 39765 and a long breaker-bar in order to unlock the fuel sender lock ring (1). Turn the fuel sender lock ring in a counterclockwise direction.
5. Remove the fuel sender lock ring (1) and the fuel sender (2) from the fuel tank.
6. Remove and discard the fuel sender seal (3).
7. Remove the fuel level sensor from the fuel sender module. Refer to Fuel Tank Pressure Sensor Replacement.




Important: 

•	Some lock ring 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.

8. Place the lock ring on a flat surface. Measure the clearance between to lock ring and the flat surface using a feeler gage at 7 points.
9. If the warpage is less than 0.41 mm (0.016 in), the lock ring does not require replacement.
10. If the warpage is greater than 0.41 mm (0.016 in), the lock ring must be replaced.

1. Install the fuel level sensor to the fuel sender module. Refer to Fuel Tank Pressure Sensor Replacement .
2. Clean the fuel sender sealing flange.




Important: Always replace the fuel sender seal when installing the fuel sender assembly.

3. Install the NEW fuel sender seal (3) to the fuel tank seal groove.
4. Install the fuel sender (2) and the fuel sender lock ring (1).

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.
5. Use the J 39765 in order to install the fuel sender lock ring. Turn the fuel sender lock ring in a clockwise direction.
6. Install the fuel pipes to the fuel sender. Refer to Plastic Collar Quick Connect Fitting Service .
7. Install the fuel sender sensor electrical connectors (1).
8. Install the fuel tank. Refer to Fuel Tank Replacement .