Fuel Sending Unit

[kodiak2]

I'm in the middle of replacing my in-tank sending unit in my '92 diesel. I found the prices anywhere from $125 to $350 locally and they all looked the same (cheap plastic). Removal from under the truck was no problem, although the quick disconnect fuel lines were not quick and did not disconnect. I had to cut them off and disassemble them on the bench. Off course the local dealer said one off the two sizes was no longer available. Found both sizes in the local NAPA store although they didn't carry the insallation tool. Will have soak them in hot water like it says on the package.
Am now waiting for the fuel tank/filler tube gasket I ordered from the dealer. I used a rubber lubricant to assemble any rubber parts which made things a lot easier. Had to replace all the hoses as the original ones had dry rot in them and half the hose clamps had to be cut off due to rust. Will report on the installation.

[KRB64]

With pictures?

Sorry you're having such trouble.

[kodiak2]

Fuel sending unit

I finally finished installing my sending unit. It took three jacks to hold up the tank and tank straps plus two dowels to align the strap holes for bolting to the frame. All the rubber components had dry-rot in them and were replaced. Using a rubber lube (ruglyde) made things a lot easier as far as reassembly of the hoses and installing the metal filler tube through the tank gasket. Working alone creates some challenges, but it can be done.
Now, the guage works sometimes so I suspect it has probems also. Of course, it is no longer available and the local junk yard wants $100. for a used one.