Leaking feul sender
Thread Starter
Drifting
Joined: Dec 2009
Posts: 1,349
Likes: 34
From: Porterville Ca
Leaking feul sender
I replaced the fuel sender and gasket 4-5 years ago and now it's leaking pretty bad. I searched and didn't find any threads. Anyone have any hints on resealing it? I got a new rubber gasket from one of the big venders. Can I assume just clean both sides of the tank and the sender and hope for the best ?
Le Mans Master
Joined: Nov 2004
Posts: 5,253
Likes: 768
From: Waterford WI
Many posts on this. Rubber reproduction o-ring and metal sealing ring are infamous for what you are experiencing. Did you soak the o-ring in oil overnight? That helps, especially if you have NOS GM parts.
Le Mans Master
Joined: Aug 2005
Posts: 6,541
Likes: 1,975
From: Temple Terrace Florida
As mentioned above, soak the O-ring in regular oil overnight. Make sure the O-ring is evenly spaced in the tank indent. Make sure the ring holding the O-ring in place is tight. I fill the fuel tank 5 gallons at a time and wait a few hours to make sure there are no leaks. Jerry
Le Mans Master
Joined: Jan 2001
Posts: 6,742
Likes: 1,384
Looks like you have a 69. I'm guessing it comes in from the bottom like my 68. My 68's has been wonderful over the years but a couple of years ago after working on my tank and removing and reinstalling it the dang thing started leaking. If you don't think it is the rubber o-ring, then it might be the metal part.
On mine it was actually the soldered metal part of the assembly.... I was surprised that it was soldered actually. Anyway, I cleaned it and removed the solder...then I BRAZED the the 2 parts together. Leak checked it over a couple of days by using paint thinner (no, not installed on the tank) over the newly brazed sections. Put it back in. Works like a dream.
By the way, I used a light coating of grease when installing the rubber o-ring.
On mine it was actually the soldered metal part of the assembly.... I was surprised that it was soldered actually. Anyway, I cleaned it and removed the solder...then I BRAZED the the 2 parts together. Leak checked it over a couple of days by using paint thinner (no, not installed on the tank) over the newly brazed sections. Put it back in. Works like a dream.
By the way, I used a light coating of grease when installing the rubber o-ring.
I replaced the fuel sender and gasket 4-5 years ago and now it's leaking pretty bad. I searched and didn't find any threads. Anyone have any hints on resealing it? I got a new rubber gasket from one of the big venders. Can I assume just clean both sides of the tank and the sender and hope for the best ?
Thread Starter
Drifting
Joined: Dec 2009
Posts: 1,349
Likes: 34
From: Porterville Ca
I replaced the seal last night after work. The old seal was destroyed! It feels like there's some sort of internal support that failed. The new one from the same supplier is fairly stiff both in bending and squeezing directions. The old one feels like spaghetti. I added 2 gallons of fuel and it held overnight. I appreciate all the input.
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Le Mans Master
Joined: Aug 2005
Posts: 6,541
Likes: 1,975
From: Temple Terrace Florida
The O-ring is immersed in motor oil according to the AIM. The oil lubricates the O-ring and offers some protection from the part of the O-ring that does come in contact with fuel. Jerry
Melting Slicks
Joined: Jan 2012
Posts: 3,039
Likes: 504
From: myrtle beach sc
Army
My 68 AIM does not show anything about lubricating or soaking the gasket. I have never done this and I have changed a few GM gas tanks in my day. I can guarantee you that the original posters gasket got eaten up by ethanol. But I have a new gasket changed about nine years ago when I changed my fuel tank and it does not leak with ethanol fuel. Lou.
Le Mans Master
Joined: Jun 2002
Posts: 8,339
Likes: 24
From: I can walk to MA
I replaced the fuel sender and gasket 4-5 years ago and now it's leaking pretty bad. I searched and didn't find any threads. Anyone have any hints on resealing it? I got a new rubber gasket from one of the big venders. Can I assume just clean both sides of the tank and the sender and hope for the best ?
For 15 years, it sat in the garage, zero miles.
Now, as I regroup to complete my journey, the fuel sender started leaking ... OUT OF THE ELECTRICAL TERMINAL !!
So, this weekend, I'm putting in a new Spectra sender unit, hope it lasts at least 15 years.
Good luck finding the cause of your leak and sealing. Hope it's just the rubber seal.