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 Fuel sender replaced! Woo hoo!

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seanb



Posts : 19
Join date : 2013-08-18
Age : 45
Location : Antioch, IL.

PostSubject: Fuel sender replaced! Woo hoo!   Thu Apr 24, 2014 2:02 pm





Replaced the fuel sender on my '95 Caprice wagon recently. I hope I don't have to do that again any time soon.
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Sprocket

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Posts : 5350
Join date : 2008-11-04
Location : Palm Beach County

PostSubject: Re: Fuel sender replaced! Woo hoo!   Thu Apr 24, 2014 5:32 pm

Glad I live in the south..... I got that job down to about 1.5 hours. I've also done it over a dozen times including the dark and rain.
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Wagoninabox

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Posts : 503
Join date : 2011-07-11
Location : Seattle Area

PostSubject: Re: Fuel sender replaced! Woo hoo!   Thu Apr 24, 2014 6:38 pm

Wow! Great use of a skateboard for sure. Be sure to use Anti-Seize when replacing under carriage bolts. It can save plenty of bloody knuckles.
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Fred Kiehl

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Posts : 4460
Join date : 2009-11-13
Age : 69
Location : Largo, FL 33774

PostSubject: Re: Fuel sender replaced! Woo hoo!   Thu Apr 24, 2014 6:57 pm

My bolts look almost like the new ones, just a little dirty. Southern cars rocks.
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seanb



Posts : 19
Join date : 2013-08-18
Age : 45
Location : Antioch, IL.

PostSubject: Re: Fuel sender replaced! Woo hoo!   Thu Apr 24, 2014 8:52 pm

Thanks everyone.  It was a learning experience for sure. I was finding little rust bits in my eyes and ears for days after. Boy what a good feeling when it started when I was finished though.
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jayoldschool

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Posts : 2413
Join date : 2009-06-14

PostSubject: Re: Fuel sender replaced! Woo hoo!   Thu Apr 24, 2014 9:00 pm

WTF if causing mine to leak when full? I replaced the sender to fix the "smells like gas when full", and it still leaks and smells. The lines are fine, the fill hose is dry, as is the vent. No cracks in tank. I dropped the tank again, removed the sender to check the gasket. You can see the staining from evaporated gas around the mounting ring. It will drip out the left side when making a turn that way. In the most extreme case, I filled up last summer on a HOT day, and parked right after with the back angled down to the left, as seen in the pic below.

I'm thinking of dropping the tank again, removing the sender, and running a couple of beads of black gasket Ultra on both sides of the gasket. Any ideas?

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Fred Kiehl

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Posts : 4460
Join date : 2009-11-13
Age : 69
Location : Largo, FL 33774

PostSubject: Re: Fuel sender replaced! Woo hoo!   Thu Apr 24, 2014 9:38 pm

I had one develop a leak a couple of years ago. The garage I used to go to smoke tested it, but it was not conclusive. I ended up replacing the tank. This spring I found the vent line cracked, and leaking. It was dripping when the tank was full. The vent line is 18mm/3/4 inch, and a PITA to find on a Saturday at 4:30. It is also a PITA to replace. You have to drop the tank to get to the inner attachment point. If you did not replace the O-ring, the old one may have taken a set from the sender, and was not returned to the original position.
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seanb



Posts : 19
Join date : 2013-08-18
Age : 45
Location : Antioch, IL.

PostSubject: Re: Fuel sender replaced! Woo hoo!   Fri Apr 25, 2014 9:01 am

I think I would've fainted if I saw that puddle under the car after changing the sender. I am glad I replaced the vent hose to the filler even though it looked good. Hopefully you figure it out, I feel your pain.
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phantom 309

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Posts : 5661
Join date : 2008-12-28
Age : 107

PostSubject: Re: Fuel sender replaced! Woo hoo!   Fri Apr 25, 2014 9:17 am

I just dropped the gas tank in the 99 chryelr town and country mini van that the wife drives,
I had to replace the brake lines from the abs pump all the way back,and the proportioning valve. The lines cuddle up to the gas tank on the way by,.15 year old quick disconnect fuel lines , don't.
of course the tank was full,..
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jayoldschool

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Posts : 2413
Join date : 2009-06-14

PostSubject: Re: Fuel sender replaced! Woo hoo!   Fri Apr 25, 2014 5:51 pm

Yes, I had to do repair kits on the quick connectors.
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