Installation of a new fuel sending unit

Is there anything special that needs to be done when replacing the fuel sending unit? It seems pretty straight forward. I have new gaskets and rings to install the unit. Should I install the unit's filter? It seems like that is something that will probably just fall off at some point in the future. I can't see a mechanism to keep it on the fuel pickup line. TIA for the advice.

 

It's more of a screen than a filter. I'd use it. It stays on the pickup by friction.

 

I got the sending unit installed and the jeep fired up. I initially only had 5 gallons of gas in the tank. After taking the jeep for a short spin, I decided to go fill it up. When the tank reached full, I had gas spurting out around the sending unit. How do I know this? The PO was kind enough to cut a square hole out of the floor of the jeep right above the sending unit.

I am not sure if the gas was coming from a leak where the sending unit mates to the tank or if it was coming from the second nozzle on the sending unit. My old unit only had one gas delivery line, this new one has two lines coming out, I tried to plug the second outlet with a piece of hose with a nut in the end. It could be coming from either side.

Like I stated before, I am using a new oring and a new locking ring. Has anyone had a similar experience with an aftermarket sending unit?

 

No. You may have misaligned the o-ring.

I did have rotten fuel hoses that leaked a lot of gas though.

 

I am going to try and realign the o-ring this evening. It seems to me that there should be a better way to make a seal at this location instead of an o-ring. Wouldn't a flat washer type rubber ring have done a better job at this?

I am having a hard time finding the o-rings on 4wd.com. Does anyone know where I can source some spares?

 

MTS has them http://www.mtscompany.com/jeep.htm - likely other places too.

 

That MTS o-ring looks more like what I thought. Can those be used with a OEM 15gal tank or does it have to be used with the MTS ploly replacement?

 

Likely you should call MTS and ask.

O-rings are not hard to source. Your local hardware store will have some (likely not the size you need though), or you can order them from places like McMaster-Carr: http://www.mcmaster.com/#o-rings/=dmwnfk