Fuel Sender Assembly Replacement Utility

Tools Required

J 44402 Fuel Tank Sending Unit Wrench

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
3. Drain the fuel tank. Refer to Fuel Tank Draining .
4. Remove the fuel tank. Refer to Fuel Tank Replacement .



5. Remove the fuel sender assembly by using theJ 44402 fuel sender locknut wrench in a counter clockwise motion.

1. Note the position of the fuel pump strainer on the fuel pump.
2. Support the pump with one hand and grasp the strainer with the other hand.
3. Rotate the strainer in one direction and pull off the pump. Discard the strainer after inspection.
4. Inspect the fuel pump strainer. Replace the strainer if it has contaminates and clean the fuel tank.
5. Inspect the fuel pump inlet for dirt and debris. If found, replace the pump..

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

1. Push on the outer edge of the ferrule until fully seated.
2. Support the pump with one hand and position the new pump strainer on pump in the same position as noted during disassembly.

1. Install a new seal, sending assembly and lock ring. Make sure the lock ring alignment holes fit over the tabs on the tank.
2. Install the cam lock assembly. Turn the cam lock clockwise to lock it.
3. Install the fuel tank. Refer to Fuel Tank Replacement .
4. Add fuel removed from the tank.
5. Connect the negative battery cable.
6. Check for fuel leaks.

6.1.	Turn the ignition ON for 2 seconds.

6.2.	Turn OFF the ignition for 10 seconds.

6.3.	Again, turn the ignition switch to the ON position.

6.4.	Check for fuel leaks.

Fuel Sender Assembly Replacement Pick-Up

Caution: 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.

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
3. Remove the pickup box. Refer to Pickup Box Replacement in Body Rear End.
4. Disconnect the fuel sender electrical connectors.
5. Disconnect the fuel sender fuel and evaporative emission (EVAP) pipes.




Important: 

•	The modular fuel sender assembly may spring up from the fuel tank.

•	When removing the modular fuel sender assembly from the fuel tank, be aware that the reservoir bucket is full of fuel. The fuel sender assembly must be tipped slightly during removal to avoid damage to the float. Discard fuel sender O-ring and replace with a new one.

•	Carefully discard the reservoir fuel into an approved container.

6. While holding the modular fuel sender assembly down, remove the snap ring from designated slots (1) located on the retainer.

1. Install a new O-ring on the modular fuel sender to the tank.
2. Align the tab on front of the modular sender with slot on front of the retainer snap ring.
3. Slowly apply pressure to top of the spring loaded sender until the sender aligns flush with retainer on the tank.

Important: Ensure that the snap ring is fully seated within the tab slots.

4. Insert snap ring into designated slots (1).
5. Connect the fuel sender fuel and EVAP pipes.
6. Connect the fuel sender electrical connectors.
7. Connect the negative battery cable.
8. Inspect for fuel leaks through the following steps:

8.1.	Turn ON the ignition for 2 seconds.

8.2.	Turn OFF the ignition for 10 seconds.

8.3.	Turn ON the ignition.

8.4.	Inspect for fuel leaks.

9. Install the pickup box. Refer to Pickup Box Replacement in Body Rear End.