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Sender Unit R&R

posted by  Steve on  Sun May 14 06:32 CST 2006
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last visit: Fri Oct 24 07:16 CST 2014
[RELATED]

I recently replaced the tie rods in my 90 745, which required raising the front end. Gas dripped out of the fuel tank when I did this and it appeared that the top of the sender unit was leaking. I removed it, stripped off all rust, treated it with MetalReady phosphoric acid, and painted with POR-15. The metal was sound. The leak resulted from a failing sender unit gasket, a large 6 inch diameter rubber seal between the tank and the sender. When you replace an in-tank pump, take some extra time to strip rust off the sender top and rustproof the unit. Replace all the hose clamps, which are invariably rusted solid, as well as the tank gasket which deteriorates and can come apart.
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