'74 CJ5 Fuel Sender Removal Help??

So I dropped my gas tank tonight in hopes of simply hooking up a wire to the fuel sender so I can have a functioning gas guage. Unfortunately, when I got it down there was no stud for a wire. There appeared to be some rubber nub with a broken wire coming out of it. I am going to replace the sender unit, but can't seem to figure out how to remove the old one. It looks like there is a ring I can pry up, but I don't want to if that isn't right. I tried to twist the whole sender unit, but it won't budge. Please, can someone clue me in as to how to remove the old sender without breaking anything so I don't have to buy a new fuel tank as well??

Thanks,
Scott

 

It actually unscrews. Its the kind of fit where you drop it in and turn it a quarter turn to lock it.
My advice would be to grab a big screwdriver and a hammer. Just tap it counterclockwise (probably) until it frees up and rotates enough to come out.

Good luck.

 

Check out the lock ring that holds it in. I grabbed the pick off ebay.

Its the metal tabbed ring next to the gasket in the bottom right.
Thats the piece you have to get to rotate a quarter turn and then everything comes off.

 

Pretty sure the rubber nub is a push on connector that goes on the threaded stud in the picture. Just yank it off and find the wire that is supposed to be hooked to it. Other wire is a ground.

 

So I few quick hits with a hammer and screwdriver and the lock ring popped out. I figured that is what was needed, but I decided to do it right this time and ask before grabbing a hammer.

Thanks,
Scott

 

Glad you got it.
Sometimes a big hammer is what's required

 

So more fuel sending unit issues. I just tried to install what I ordered from 4wd.com, and it doesn't fit. I mean the lock ring will not fit over the 2 barbs on the top of the sending unit even though I ordered the kit from them. I try to put it on over the barbs, but the distance between the 2 is greater than the diameter of the lock ring!?! It also almost seems like the sending unit is too long, although it matches with what the part numbers say online. Anyone have any ideas? Looks like I will be calling customer service tomorrow.

Thanks,
Scott

 

Is it a replacement from crown? I had the same issues and ended up returning it and fixing the one that was in my tank.

 

I have the same issue with my '74 sending unit. In this case the PO saved me some hassle and cut the floor out so that I have easy access to it without the need to drop the tank.

I have checked continuity from the sending wire to the fuel gauge and it is good. There is no ground wire to speak of. Where is the best place to establish a ground? Does the ground wire connect to the same post as the sending wire?

Any detailed pictures of an install would be great. Every picture I have found online has just added to the confusion.

 

Yes this is a Crown replacement. I have a call in to 4wd.com and am supposed to send them pictures. At first they told me to bend the piping to make it fit, which I told them no thanks. Then they tried to say the lock ring was wrong maybe and they would send another. Finally they said to send pictures and they would take a look. My fear is that I got a 20gal. sender or some other sender in the correct box for my application. At least they are working on it for me! Time will tell. I would like to fix the original, but when I pulled it out the float for the fuel level was missing (probably in the bottom of the tank).

Thanks,
Scott

 

Hmm, wish I could be of more help. When I replaced mine it fit.
Bummer, I'm betting you got the wrong part.

How does it compare to the old one? - Just to make sure you're not putting it together wrong or something.

 

It's definately different than the original because the original never had a fuel return port like the replacement. I couldn't find a replacement with only a fuel feed port, so I got the one listed for my year/application. Hopefully it gets fixed soon.

Scott

 

The one I got from 4WD also has the return port but it fit without massaging it. Just capped the return port.

 

The lock-ring will sufficiently ground the sender to the tank but you will need a ground wire from the tank to the frame. Don't put it on the the same term as wire to gauge.

 

Yeah, I have already bought some hose, bolt, couple of clamps for capping off the return port. Now I just need the parts to fit nicely. All in good time I suppose. Just frustrating to get a part, and then have to wait for the right one. Oh well.

Thanks,
Scott

 

What about the lock ring and sender unit, are they the same diameter as the old ones?

 

So 4wd.com told me to squeeze the supply and return ports together to fit the lock ring over the sender, and if it failed they would send new under warranty. Not my favorite answer, and I could have probably fought it to get a new one sent now, but I want to have a Jeep I can move again (without pushing). So I squeezed with some channel locks and now the lock ring fits. I put it together and my only complaint is that the sending unit seems a touch loose in the tank (yes the gasket is installed). I just hope my gas isn't gonna evaporate or water get in, but I drove it to the carwash on Saturday and it seemed to work.

Scott

 

SCOTT,
I've got to replace the sender on my '75, iot leaks when the tank is full,,, ,, if yours is a "a touich loose in the tank" be carefull when you fill the tank!!!!! For sure water is not good to have leak in, but much worse is a lot of fuel leaking out as you are filling the tank !!!!
When I do get around to replacing it, I will surely cut an access way through the fiberglass floor to get to it... rather than having to remove the tank....