removing fuel gauge sender, w/o damaging float arm

auditude at neta.com auditude at neta.com
Thu Aug 31 21:28:59 EDT 2000


Patient is an '88 5kcstq.

I need a new fuel gauge sender.  I broke mine while trying to 
remove it.  I took some pics, so that others could benefit from 
knowing how the sender arm is supposed to be removed from the 
sender before removing it all from the tank.

Come to find out my mechanic didn't put the fuel pump exactly in 
it's place the last time he was in there.  Funny, I remember him 
telling me that I didn't put it in correctly, and that he fixed it and 
charged me for it.

I wouldn't have broken the sender, if the banjo bolt wasn't so damn 
tight that it split the plastic in half when the molded-into metal 
insert broke out of the plastic assembly.

It already needed to come out, because the arm was catching on 
something.

To make matters worse, I think I damaged the hose that goes onto 
the sender, held on by the banjo bolt.  How far forward does that 
hose go?  Can I fix just the end of it, or do I need to replace the 
whole hose?

I'm still uploading pics, but here's the address to a webpage with 
some big, high-res pics of what the connection looks like, where 
the arm attaches to the pivot on the sender.

http://www.neta.com/~auditude/fuelsender.html

Warning, this page is a bandwidth hog.  I didn't optimize anything 
for low-bandwidth.

If anyone has a sender they would like to sell or give away, or know 
where I can get one for a reasonable price, please let me know.

I am sending out some inquiries to various vendors.  TPC says that 
it's dealer only.  Clair is included in my mass inquiry.

Thanks,

Ken



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