Fuel Gauge Sender: Service and Repair
TOOLS REQUIREDJ 44402 Fuel Tank Sending Unit Wrench
REMOVAL PROCEDURE
CAUTION: Refer to the Battery Disconnect Caution in Cautions and Notices.
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure (Pickup) or Fuel Tank Draining Procedure (Utility with Single Tank) or Fuel Tank Draining Procedure (Utility with Dual Tanks - Front Tank) or Fuel Tank Draining Procedure (Utility with Dual Tanks - Rear Tank).
4. Remove the fuel tank.
NOTE: 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.
5. Remove the fuel sender assembly retaining ring using the J 44402 fuel tank sending unit wrench.
6. Remove the fuel sender assembly and the seal. Discard the seal.
CAUTION: Refer to Approved Container Caution in Cautions and Notices.
7. Clean the fuel sender sealing surfaces.
INSTALLATION PROCEDURE
CAUTION: Refer to Fuel sender gasket caution in Cautions and Notices.
1. Install the new seal on the fuel tank.
IMPORTANT: The fuel pump 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 pump strainer does not block full travel of the float arm.
2. Install the fuel sender assembly into the fuel tank.
NOTE: Refer to Fastener Notice in Cautions and Notices.
3. Install the fuel sender assembly retaining ring using the J 44402 fuel tank sending unit wrench.
4. Install the fuel tank.
5. Refill the fuel tank.
6. Install the fuel filler cap.
7. Connect the negative battery cable.
8. Inspect for leaks.
8.1. Turn the ignition ON for 2 seconds.
8.2. Turn the ignition OFF for 10 seconds.
8.3. Turn the ignition ON.
8.4. Inspect for fuel leaks.