Replacing Fuel Sending Unit

[erik70rt]

Now my Challenger has started dripping fuel from the sending unit.  Ugh.   

Has anyone ever replaced one without dropping the tank?  Is it possible or should I bite the bullet and drain/drop the tank?

[GoodysGotaCuda]

It's fairly easily accessed on the side of the tank. Get it relatively low on fuel and be sure to use a brass punch or something non-sparking for the lock ring.


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[soundcontrol]

You don't have to drop the tank, mine came out fine.

[erik70rt]

I have the lock ring tool so I'm not worried about that.

[RUNCHARGER]

It's actually quite easy.

[erik70rt]

I assume I'll have to remove the muffler to get the sending unit out of the tank.

[Burdar]

Possibly muffler and heat shield.  Getting a muffler loose from the pipe is a PITA.  I'd rather drop the tank then fight removing a muffler.

[erik70rt]

I put the exhaust on about two weeks ago, and only has about an hour of run time on it, so hopefully it won't be too hard to take apart.

[Burdar]

Regular factory style clamps will crimp the pipe/muffler together making it hard to disassemble.  When I used to work at a muffler shop, we had to heat up the ends red hot to get them loose.  Hopefully you didn't tighten them down too much.