Express 2500 V8-6.0L VIN U (2006)
Fuel Level Sensor: Service and Repair
Fuel Sender Assembly Replacement
FUEL SENDER ASSEMBLY REPLACEMENT
TOOLS REQUIRED
J 45722 Fuel Sender Lock Nut Wrench
REMOVAL PROCEDURE
1. Disconnect the negative battery cable.
CAUTION: Refer to Battery Disconnect Caution.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
4. Remove the fuel tank.
5. Use the J 45722 and a long breaker-bar in order to unlock the fuel sender lock ring.
NOTE:
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Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring.
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Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints.
IMPORTANT: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not
recommended. Secure the fuel tank in order to prevent fuel tank rotation.
6. Remove the fuel sender assembly and the seal. Discard the seal.
7. Clean the fuel sender sealing surfaces.
CAUTION: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury.
Never store the fuel in an open container.
