replacing fuel sender

[oldbuck]

Haven't tried this repair before - any tricks? Is there a certain sealer compound I need when installing the new unit to the tank?

A year or so ago a friendly boater helped himself to the fuel in our tank one night - ever since then the dash guage bounces around +/- a quarter tank while boating.

Other than not smoking while working on the tank and not illuminating the fuel tank level with a lighter, is there anything I should know?

The boat is a cobalt 220 with 7.4 merc I/O. Tank is plastic(?) 54 gals.

thx,
-d

 

[Fireman431]

Re: replacing fuel sender

I assume you have a float-style sender with 5-6 screws on the top?

Follow the directions that come with it. Disconnect the battery terminals so there are no accidental sparks. Remove the wires attached to the top of the sending unit. Note where they go. The black is the ground and the (usually) pink goes to the gauge.

The only work you may have to do is cut and bend the float level if you purchased a universal kit. The gasket is usually a cardboard type and comes with the gauge. No other sealer needs to go in there.

Reverse the process to close it back up. I have always connected the wires back up with the sender out of the tank to verify that is works, but that's your call. Expect some gauge fluctuations while the boat is moving as there is always fuel sloshing around inside tha tank. Your gauge may not be bad. How does it read while settled in the water and still? That's the reading I would go with. That and always remember the 1/3 rule:

1/3 for the trip out
1/3 for the trip back
1/3 for the reserve

It's been a few years since I changed a fuel sender so I hope I didn't forget anything. Please don't shhot back hateful posts if I did. Simply add the info after this.

 

[oldbuck]

Re: replacing fuel sender

right fireman, 5 screws w/pink wire to the center terminal & black wire to the cover plate.

The guage reads fine if the boat is still, but spastic when in the water. It used to be very smooth so I assume when my 'friends' pushed their siphon hose into the tank they somehow bent or damaged the float.

it's not a horrible problem, just annoying.

thx for the heads up,
-d

 

[Flyvet]

Re: replacing fuel sender

I'm not how accessible your tank is but in my flats skiff it was accessed through a round 6 inch or so diameter hatch on the inside of the front locker. I needed a ratcheting right angle screwdriver and a square bit to remove the screws. It was too difficult for my large hands so I got the jig saw out and installed a larger rectangular hatch, it made it much easier but still had to hang my head upside down. Even though the sending units are inexpensive I would first check to be sure the wire leads are in good shape and hit them with some sandpaper.

 

[DaNinja]

Re: replacing fuel sender

I replaced one last fall in the Starcraft. One thing I found, after much aggravation, the bolt pattern is directional, (at least it was on mine).
The five holes looked evenly spaced, but in fact there was only one way that they all lined up. Mine had to face starboard.

 

[scutly]

Re: replacing fuel sender

replaced mine yesterday after i ran outa gas and had to get towed. :redface: got a universal kit made by moeller. it came with a nice thick rubber gasket and the underside of the screw heads had some kinda sealant on them. the screws could have had bigger heads on then though so a 1/4"drive socket would grab them better. no way i was getting my hands in there with a screwdriver. i can't see my fuel gauge with my head buried in the bilge, so i pulled my dash and hooked the sender right to the back of the gauge with jumper wires to test everything before i installed it.