1G AWD fuel sending unit broke!

[racinmasonc]

Hey guys just wondering what i should do? the fuel line coming off the sending unit was so rusty it moved back and forth maybe 2 times and pretty much it was snapped off... also what size are those top bolts on the sending unit to the tank?? i can't find any size that fits!!!! i have a guy that has a 91 awd and he's pulling the tank and giving me the tank and sending unit but i hope he doesn't break it either! if he does is the only other route to get the fuel line kit??? let me know asap!!!! its the only thing i need to get my car running!!!

 

[malcvr4]

Try a 8mm socket. If you cant get another sending unit you may be able rig something up with a brass compression fitting from the hardware store.

 

[racinmasonc]

hey its not an 8mm socket....8 is too big and 7 is too small..... also 5/16 fits on but is a little too big... the next size smaller is too small... !! is it a 7.5mm????????? or what?

 

[malcvr4]

hey its not an 8mm socket....8 is too big and 7 is too small..... also 5/16 fits on but is a little too big... the next size smaller is too small... !! is it a 7.5mm????????? or what?

I just checked mine and the 8mm and the 5/16 work. Good luck

 

[racinmasonc]

question are the 90-91 AWD the same?? i got a buddy with a 91 that is going to sell me the whole tank and fuel sending unit assembly

 

[turbo2086]

Ya, I believe they are the same. Mine broke too. I made creation out of the fuel AN fittings. The blue and red ones. I have a picture of it. I'll get it up soon, and show ya what I did.

 

[steve]

Originally they were 8mm nuts but after corroding for a while they are a custom size.
On a couple I had to resort to a good vice grip to work them loose.

Steve

 

[racinmasonc]

oh nice! this should be fun!! haha

 

[underradar92]

Don't forget the PB blaster! or something like it, but PB works awesome.

 

[steve]

I spent a week prior to attempting to change the pump soaking the studs and nuts with PB Blaster. I hit them with a brass wire wheel on the Dremel to break up the rust and soaked them again before putting a wrench to them.

I gently worked the nuts back and forth while clearing the threads with PB Blaster to get them off without breaking any of the studs. I didn't want to drill any of them out to replace. I'd already heard what fun that is.

Steve

 

[racinmasonc]

i read that some people who have broken most of the studs all you gotta do is use JB weld all the way around the sending unit on the tank... would that work?

 

[steve]

iWould that work?

I wouldn't trust my life to a glued on fuel pump.

Steve

 

[OreoTsi]

did ya find a fix to the cracked fuel line? Mine was rusted to hell and snapped off when i tried putting in my 255 tonight. I'm gonna see if i can order a replacement pump assembly at work tomorrow.

 

[racinmasonc]

a guy i know is selling me the tank and fuel sending unit and his is near perfect! he said theres no rust! woohoo!!!

 

[jepherz]

racin, you're the first person I've seen on here from Rochester. Let me know if you want to meet up some time.