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WARNING! Check Your Reproduction Gas Sending Unit
#1
I filled up my tank a couple of days ago in my 73 Convertible and noticed a fuel odor in my garage the next day. I checked under the car and noticed some drips of gas under the gas tank and fuel sending unit. I replaced the fuel tank and sending unit back in 2005 and used one of the spring tension hose clamps (like stock original) and it appeared the hose was leaking so I added a worm type hose clamp. The next day I checked it again and was still leaking. After looking closer it appeared the gas was coming out of the electric terminal boot that presses onto the sending unit. After counting my blessings that the gas was not ignited by a spark in the terminal, I disconnected the battery and removed the boot and sure enough fuel was leaking around the black gasket area of the terminals. So I drained the tank with a hand siphon pump and will be ordering another sending unit. I need to double check where I bought it and give them a call to see if they have had any similar reports. Although the tank and unit has been on the car about 6 years I doubt if I have driven it more than 1,200 miles.

So if you have replaced your fuel sending unit with a reproduction you should check it out to make sure there is no leak into the terminal boot!

I had already wiped the drip off the terminal lead in the picture, but you can see [/b]the black gasket is damp from gas!

[Image: DSCF0886.jpg]



Mike AKA Ole Pony & Rare Pony

Our current Mustang garage/driveway
1973 Mustang Convert - Bought in 1974 - Still have it!
2004 Mach 1 Oxford White Auto, Bought Sept 06


[Image: 20180127_082009.jpg]

upload a photo on internet




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#2
THANK YOU!!! for the info!!
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#3
Nice catch, glad you caught it before any serious heartache.

Steve



[Image: 25yvyp3.jpg]
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#4
i had this same problem 4 years ago.

leaking out of the connector plug as well.

your sender is also the same defective version i got where the fuel outlet pipe is welded the wrong way.

here is a picture of my older sender that was defective and leaked as well.

[Image: 1.jpg]

when i bought the 2nd one. i went for the stainless steel version with the brass float not plastic float
and it didn't leak and the outlet tube was routed correctly.

you want the fuel tube facing the front of the car like original
[Image: 100_1463.jpg]


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#5
72HCODE;22907 Wrote:i had this same problem 4 years ago.

leaking out of the connector plug as well.

your sender is also the same defective version i got where the fuel outlet pipe is welded the wrong way.

here is a picture of my older sender that was defective and leaked as well.

[Image: 1.jpg]

when i bought the 2nd one. i went for the stainless steel version with the brass float not plastic float
and it didn't leak and the outlet tube was routed correctly.

you want the fuel tube facing the front of the car like original
[Image: 100_1463.jpg]

I noticed the different direction of the tube when I first bought it, but it worked so I was not concerned at the time. Good tip on the stainless steel.



Mike AKA Ole Pony & Rare Pony

Our current Mustang garage/driveway
1973 Mustang Convert - Bought in 1974 - Still have it!
2004 Mach 1 Oxford White Auto, Bought Sept 06


[Image: 20180127_082009.jpg]

upload a photo on internet




  Reply
#6
by having the hose backwards i noticed it was more likely to kink, and i did not like how it sat under the lip of the fuel tank, but it worked.

I later discovered my original fuel line in that area was bent up incorrectly as well.

the direction of the outlet pipe will tell you if you ordered the newest version of the sender.

the calibration of the reproduction fuel sender is still terrible, and you have to bend the float arm to get it close.

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#7
I just went through this.

Don at Ohio Mustang got me fixed up with the correct sending unit.

73 conv. 460, D0VE large valve heads, Performer RPM manifold, Voodoo 227/233 cam, Holley 950 HP carb, C6 trans, 3.25 trak-loc.
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#8
I know others had the same problem w/the repo sending unit and it was fixed after replacing it. My main concern is the fuel hose, its too close to the tailpipe. Ive been told it can heat up &maybe ignite. I'm thinking about putting a metal shield so it doesn't melt from the heat coming off the exhaust pipe, plus other safety issues. Any suggestions?
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#9
the heat from the exhaust after the mufflers is pretty low, i was concerned about the same thing, i kept checking it and noticed no issues, its not a very good design but it works. no matter how you try and hold the wire for the fuel sender plug it always makes its way over near the tailpipe and touches it sometimes, I've seen it on numerous cars, but the temp is low at that point and doesn't melt the wires.

running 2.25 and 2.5" exhaust pipes makes things worse, i kept making sure i had at least a pinky finger of clearance for the fuel hose. at this point I'm more concerned about getting rear ended and having the tank burst open.
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#10
sharpstang72;22936 Wrote:I know others had the same problem w/the repo sending unit and it was fixed after replacing it. My main concern is the fuel hose, its too close to the tailpipe. Ive been told it can heat up &maybe ignite. I'm thinking about putting a metal shield so it doesn't melt from the heat coming off the exhaust pipe, plus other safety issues. Any suggestions?

You can use a piece of heater hose slipped over the fuel line to act as a heat shield/sleeve if you concerned. I'd be afraid the metal might chafe.

73 conv. 460, D0VE large valve heads, Performer RPM manifold, Voodoo 227/233 cam, Holley 950 HP carb, C6 trans, 3.25 trak-loc.
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