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Username Post: Need to remove fuel guage sender        (Topic#344127)
"6th Year" Silver Supporting Member
Posts: 876
Loc: Sanford NC
Reg: 08-27-03
04-18-17 02:44 PM - Post#2687180    

My fuel gauge sender has developed a leak by the fitting. Any tips on changing this out. Is it easier to drop the tank? I don't have a lift. Are the senders all the same? Rubber or Cork? Thanks

Edited by carolinakid on 04-18-17 02:46 PM. Reason for edit: No reason given.


"13th Year" Gold Supporting Member
Posts: 1880
Loc: Dallas, TX
Reg: 05-17-04
04-18-17 08:08 PM - Post#2687258    
    In response to carolinakid

Tri Five fuel senders can be removed without removing the tank. The fuel level should be half full or less though. The sender and fuel outlet are all in one unit located at the front of the tank, accessible from under the car.

'57 210, 327 cid, Holley MPFI, 700R4, A/C & more.
'51 Studebaker Starlite coupe, 350, TH400, GV OD.
'96 Replica of a 1950's Teardrop Trailer.

"6th Year" Silver Supporting Member
Posts: 876
Loc: Sanford NC
Reg: 08-27-03
04-19-17 01:28 AM - Post#2687273    
    In response to 5Larry7

Thanks for the info. I noticed Danchuk sells a "Best" and a "Good" Sending Unit. Do you know what the difference is?

Valued Contributor
Posts: 2955
Loc: Cameron, Wi, USA
Reg: 11-09-01
04-20-17 07:48 AM - Post#2687456    
    In response to carolinakid

I would always go for best on a item like that. Get new screws with copper washers and composite gasket.

57 Bel Air 2dr Ht
327 700r4

"2nd Year" Silver Supporting Member
Posts: 91
Loc: Kansas
Reg: 08-26-08
04-20-17 07:55 PM - Post#2687539    
    In response to carolinakid

Ditto on the copper washers and new screws, the washers help seal leaks coming up the threads and out under the screw heads.


Big T 
"11th Year" Silver Supporting Membe
Posts: 2679
Big T
Loc: Simi Valley CA
Reg: 04-14-06
04-21-17 01:40 AM - Post#2687562    
    In response to mike56

The better gasket IMO is rubber. Others favor cork. I believe my unit came with a cork gasket. They sell the rubber gasket as a separate item.



55 4 door BelAir

"10th Year" Gold Supporting Member
Posts: 807
Loc: Pasadena, Texas
Reg: 04-29-04
04-28-17 07:58 PM - Post#2688787    
    In response to carolinakid

If it was me I would add the shunt wire to the new sender

VC56S 2 door Sedan, 36 Years


"6th Year" Silver Supporting Member
Posts: 876
Loc: Sanford NC
Reg: 08-27-03
05-02-17 07:15 AM - Post#2689297    
    In response to Bad56Sedan

Bought new sender. It was easier for me to just remove the tank to replace sender. Danchuk actually has instructions for changing out senders. Old sender had in addition to a crack at fitting there were several cracks in float.
Plan on saving old sender as a spare. Ohmed out correctly. Went to repair loose fitting by reheating solder without much luck. Cleaned pipe and fitting and used JB Weld. Haven't a clue if JB Weld will holdup. Cross that bridge if new one ever goes bad. Is a shunt the same as a ground?
Thanks to all for responding

Posts: 216
Loc: seligman,arizona
Reg: 05-14-09
05-02-17 07:40 AM - Post#2689298    
    In response to carolinakid

a shunt (simplified) is a small wire that takes power from a large wire for what ever it is needed for.

Lee T 
Posts: 126

Reg: 07-05-12
05-02-17 02:02 PM - Post#2689332    
    In response to Big T

Cork is not compatible with ethanol, neoprene rubber is compatible.

Honored Member
Posts: 27096
Loc: Katy, Tx, USA
Reg: 07-06-00
05-02-17 04:57 PM - Post#2689353    
    In response to Lee T

The "best" Danchuk sender comes with a cork/rubber gasket and a better float. That's the one you want. The other one comes with an inferior Chinese brass float and a rubber gasket that leaks.

Most guys have the best luck with a cork/rubber gasket - even if cork is incompatible with ethanol. Many complaints here and on other forums about rubber gaskets leaking.

As said, you need to get the Danchuk sealing washers for the screws. Also use some non-hardening sealer on the screw threads. Permatex #2 works well.

The bolt hole pattern in the sender/gasket/tank is not evenly spaced. Make sure the hole pattern on the gasket lines up correctly. On some gaskets there is a notch or tab on the outside, line it up with the "dot" on the sender.

Senior Member
Posts: 1366

Age: 62
Loc: Camas, WA
Reg: 07-30-06
05-09-17 10:09 PM - Post#2690529    
    In response to carolinakid

The fuel pickup tube that passes thru the sender is soldered in place. A small torch is best to heat the joint sufficiently to seal a crack. You will need a coil of acid core solder to make a leak proof repair. Obviously, DO NOT attempt this with the sender anywhere NEAR the tank!
It may make it easier to leave the tank straps slightly loose when lining everything up. I did this job on a '55, 57 may be different. There must be NO strain on the pickup tube to get threads started on the fuel line. If so, you WILL crack that solder joint. I did mine in my memory may be a bit....fuzzy


Chevrolets previously owned:
1947 Fleetline Aerosedan
1955 Bel-Air 4 Door Sedan
1958 Biscayne 2 Door Sedan
1977 Monte Carlo

Currently own:
1957 Bel Air Sport Coupe


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