Fuel gauge sending unit

[BubMullen]

I bought a new sending unit from Tom’s. After I pulled the old unit out I couldn’t get the new unit to fit in flush with the tank. Is there a trick?

If not I found the float was gone from the old unit. I checked the ohms and swapped the float over. But I can’t get the rubber gasket in between the unit and the tank. Help?

 

[JeepGuy]

There are two small metal tabs on the backside (in tank side) of the sending unit that hold it in place. I just replaced mine and had to bend them a little in to make it fit. They are there to align your sending unit to the arm swings properly so you don't want to remove them, but you might have to adjust them a bit and just find the right angle.

 

[BubMullen]

Thanks, I trid that last night (yes they were off a bit). But the circle part seems a hair too big to fit where you place it and lock it in. WEIRD

 

[JeepGuy]

I've always had to angle them a bit to get them to go in. Never had on that you could just go straight on in one shot. Biggest issue there is ensuring that the little rubber O-ring between the sending unit and tank does not move. I've had pretty good success with using a tiny bit of RTV on a couple spots of that ring that helps it sit in the valley like it's supposed to. You definitely do not want to put a ton on there, just a little bit to help hold it.

I've had to replace three of these things over the last year for various reasons. Only one of the three was a success on the first try. The other two both required some verbal and physical persuasion.

 

[BubMullen]

Thanks for the info. I was thinking I had lost my mind !

 

[BubMullen]

another question, I bought some new fuel line and it seems too small. The line they gave me will not fit over the sending unit connection nor the other line under the Bronco. Anyone know what size I need, or should I just get something slightly bigger

 

[Oldtimer]

My research (paper, not actual) tells me when Bronco went from 289s to 302s, the fuel line went from 5/16 to 3/8 inch.

 

[BubMullen]

that would do it !

 

[BubMullen]

bought the 3/8 and worked like a charm ! Thanks guys !

 

[SouthPaw74]

Just replaced my unit this past weekend. Grease on the o-ring made a big difference! Gas gauge now works and no leaks from the sending unit so far!