Fuel sending unit gasket replacement

DeathRex · Post by **DeathRex** » 05 Aug 2016, 10:08

I was smelling a fuel order, and saw a ring around the top of the fuel tank, so I ordered the 2 sized hose on the top of the tank, the fuel sending unit gasket and the fuel pump gasket. Since I could unscrew the fuel sending unit nut, I replaced the gasket. But now I can't get the nut on without cross threading it, I've tried about 5 dozen times. The nut itself seems really loose, and I can put it on as long as the pesky sending unit is out of the way.

I also can't seem to get fuel sending unit's nut close to lined up in the hole. I've loosened the tank bolts, and have to pry against the fuel pump nut so I can get my pliers in.

Post by **scot850** » 05 Aug 2016, 10:48

There a is fair chance the threaded nut has past its sell by date. I know many guys re-use these, but the plastic over 16+ years degrades. So my recommendation is to replace it especially as it feels loose. Also make sure the rubber gasket is not interfering with the nut catching the first thread correctly.

Neil.

PS78 · Post by **PS78** » 05 Aug 2016, 11:48

When my sending unit quit working, I encountered the same problems you're having with the nut not catching the threads. As mentioned above, there is probably warpage after a long service life. After a number of futile attempts I decided to go an unconventional route and seek out a different gasket seal in the form of an o-ring that closely matched the diameter and thickness of the Volvo gasket and was fuel resistant from a hardware supplier. It fit well on the unit and against the tank but allowed me to get the original sending unit nut to thread on and seal. No fuel odors, no leaks, no evap codes,it worked like a charm. If you want, I can get you the SKU later on.

beigg · Post by **beigg** » 05 Aug 2016, 20:26

PS78 wrote:When my sending unit quit working, I encountered the same problems you're having with the nut not catching the threads. As mentioned above, there is probably warpage after a long service life. After a number of futile attempts I decided to go an unconventional route and seek out a different gasket seal in the form of an o-ring that closely matched the diameter and thickness of the Volvo gasket and was fuel resistant from a hardware supplier. It fit well on the unit and against the tank but allowed me to get the original sending unit nut to thread on and seal. No fuel odors, no leaks, no evap codes,it worked like a charm. If you want, I can get you the SKU later on.

Nice alternate to a rather parts procuring challenge.