Fuel Sending Unit Repair for C2 Needed

[Gary J.]

Re: Fuel Sending Unit Repair for C2 Needed

James, thanks for the update and the pictures. Even though it was a long wait and expensive at least there is a source now for having our original units repaired.

[Leif A.]

Re: Fuel Sending Unit Repair for C2 Needed

James,
Look GREAT!! Here's hoping it performs as good as it looks. Did you soak the O-ring in oil before installing?

[James W.]

Re: Fuel Sending Unit Repair for C2 Needed

Leif,

Yes I did. It was not difficult to get the lock ring in place, but it is tight.

James

James,
Look GREAT!! Here's hoping it performs as good as it looks. Did you soak the O-ring in oil before installing?

[Gary B.]

Re: Fuel Sending Unit Repair for C2 Needed

Update on my fuel sending unit repair. On Friday, June 23rd I received my sending unit back from being repaired and restored by Bob's Speedometers in Howell, Michigan. As I stated in an early reply to this post, I sent it to them during the third week of February of this year. They did an excellent job and after being bench tested before installation and tested again once installed in a dry tank it works as required 0.2 ohms at empty and 89.8 ohms at full with good linier readings when moving the float arm from empty to full. I had asked them in my letter which was sent with the sending unit that I did not want the sening unit plated, but they either didn't read my letter or that is just standard practice when they restore them. I have to say it looks great, and I'm glad now after seeing the end result that it was worth it. So the final price... are you all sitting down? $575.00 plus return shipping for a total of $604. Expensive yes, but worth it so far to have the original AC sending unit back in the tank. My only hurdle now is that when fuel is put in the tank that it doesn't leak. I installed it per the instructions in the '65 AIM using an NOS GM rubber O-ring. I took the advice from fellow members and applied so fuel proof sealer on the inside wire connectors for good measure. I plan to put a gallon or two of gas in te tank next week and let it set for a day or two and monitor it for leaks. I've attached a few pictures of the restored sending unit. Let me know if you have any questions.

Thanks,

James

[Steve E.]

Re: Fuel Sending Unit Repair for C2 Needed

If anyone is looking to sell an original AC sending unit for a 63 let me know. I would like to replace my reproduction unit.
Thanks,
Steve

[James W.]

Re: Fuel Sending Unit Repair for C2 Needed

Is there a difference between a 1963 gas tank sending unit and sending units from 1964 through 1967? If there isn’t, I have a few but they all need to be rebuilt/restored. Some of these I believe are from 1968 and up Corvettes, but not sure, they just appeared one day in the back of my truck. Send me a PM.

James

If anyone is looking to sell an original AC sending unit for a 63 let me know. I would like to replace my reproduction unit.
Thanks,
Steve

[James W.]

Re: Fuel Sending Unit Repair for C2 Needed

An update on my original rebuilt/restored fuel sending unit. After installation, I put 3 gallons of gas in the tank to leak test the sending unit O-ring and electrical connector seals. After 48 hours it is leak tight. The issue now is that with 3 gallons in the tank at normal vehicle ride height, it only registers just above empty, about two needle widths. In my opinion, it should be reading higher since 5 gallons would be approximately 1/4 of a tank. I'm wondering if I need to drain the tank, remove the sending unit, and carefully bend the float arm down slighlty so that the float will sit lower in the tank and show a higher level of fuel or just leave it as is?

Any other suggestions would be great.

James

[Terry M.]

Re: Fuel Sending Unit Repair for C2 Needed

James,

Since you bench tested the unit and verified operational accuracy, I think you would be ok to remove the unit and bend the arm slightly. That said, I would recommend checking the guage at a couple intervals of filling the tank. Since the tanks hold 20 gallons, I suggest you fill first with 5 gallons and check the guage reading. Should be close to 1/4 full. Then fill with 10 gallons total and check the guage again...should be near 1/2. You could do the same for 3/4 and full by adding the needed fuel. That will give you an accurate representation. If the results you get indicate inaccurate readings, you may need to bend your float arm a bit. Unfortunately, that will be a "best guess" thing. Removing the fuel and, then, the sending unit is the tedious part. However, if you want (need) to get the sender and guage in sync, that may be necessary. If you do need to bend the float arm a bit, I'd recommend using caution and go a little bit at a time. You should be able to see results by refilling the tank only to the 1/4 full step. That would help in not having to remove a full tank of fuel if your first try is not good enough. Anyway, that's what I would do.

Terry

[James W.]

Re: Fuel Sending Unit Repair for C2 Needed

I was going to add another 5 gallons to get me to 1/4 of a tank and recheck the gauge reading. I just don't want to have to pump off 20 gallons of gas if I don't have to.

James,

Since you bench tested the unit and verified operational accuracy, I think you would be ok to remove the unit and bend the arm slightly. That said, I would recommend checking the guage at a couple intervals of filling the tank. Since the tanks hold 20 gallons, I suggest you fill first with 5 gallons and check the guage reading. Should be close to 1/4 full. Then fill with 10 gallons total and check the guage again...should be near 1/2. You could do the same for 3/4 and full by adding the needed fuel. That will give you an accurate representation. If the results you get indicate inaccurate readings, you may need to bend your float arm a bit. Unfortunately, that will be a "best guess" thing. Removing the fuel and, then, the sending unit is the tedious part. However, if you want (need) to get the sender and guage in sync, that may be necessary. If you do need to bend the float arm a bit, I'd recommend using caution and go a little bit at a time. You should be able to see results by refilling the tank only to the 1/4 full step. That would help in not having to remove a full tank of fuel if your first try is not good enough. Anyway, that's what I would do.

Terry

[Terry M.]

Re: Fuel Sending Unit Repair for C2 Needed

What I outlined is obviously not a simple process. That said, if you wish to check for true accuracy, it might be the best way. I can't tell you how many times I have removed fuel from my tank using my hand operated "rabbit pump". I should have my head examined.

Terry

[James W.]

Re: Fuel Sending Unit Repair for C2 Needed

I'm gong to put the additional 2 gallons in the tank tonight and recheck all the wiring connections and the grounds. If I'm not close to 1/4 tank level, I'll pump the fuel off and remove the sending unit to "adjust" the float arm this weekend and report back.

Thanks for taking the time to give me your input and experience.

James

What I outlined is obviously not a simple process. That said, if you wish to check for true accuracy, it might be the best way. I can't tell you how many times I have removed fuel from my tank using my hand operated "rabbit pump". I should have my head examined.

Terry

[Terry M.]

Re: Fuel Sending Unit Repair for C2 Needed

James,

Too bad we don't live closer to one another. I could just run over with my "rabbit pump" and we could do it together

[Ronald L.]

Re: Fuel Sending Unit Repair for C2 Needed

One comment on the plating...it looks bright & shiny, fwiw that is not the AC Spark Plug coating. Do they say what it is? bright Zinc or turn coating?
The original was dull.

I wouldn't want mine glossy and I doubt from what I've read, driving out and talking to them in person won't change the result...

[Ronald L.]

Re: Fuel Sending Unit Repair for C2 Needed

James,
What did you use as a fuel tank sealer, this hot epoxy?

Got a zip coupe neck that is leaking out the bolt threads ...

[Leif A.]

Re: Fuel Sending Unit Repair for C2 Needed

James,
What did you use as a fuel tank sealer, this hot epoxy?

Got a zip coupe neck that is leaking out the bolt threads ...

Ronald,
Get yourself some new screws with the rubber washers attached...they all get rotted over time.

https://www.zip-corvette.com/63-74-gas-tank-filler-neck-screw-set.html