Replacing The Fuel Sending Unit In Your Classic 65 Mustang

If your 1965 Mustang's fuel gauge is inaccurate or not working, you may need to replace the fuel sending unit. This unit conveys to the fuel gauge the amount of gasoline in the tank, and sometimes they quit working and need replacement. The replacement process is quite simple and can be done by most home mechanics. This guide will walk you through the steps to replace the fuel sending unit in your 1965 Mustang, ensuring your fuel gauge works accurately.

Jack the car up

Jacking up your car is an important step in the process of replacing the fuel sending unit of your 1965 Mustang. Here is a detailed, step-by-step guide on how to do it safely and effectively:

Firstly, ensure you have the necessary tools and equipment for the job. You will need a jack and jack stands or a lift to elevate your vehicle. It is crucial to use a sturdy and stable jack that can bear the weight of your Mustang. Additionally, you will need a flat workspace, such as a garage floor or a level surface, to position your jack and car.

Once you have gathered the required tools, position your Mustang on the flat surface and engage the parking brake. This will prevent the car from moving during the jacking process. Now, locate the jacking points on your Mustang. These are the reinforced areas on the frame of the car that can bear the weight of the vehicle when lifted. Consult your owner's manual or a repair guide specific to your 1965 Mustang model to identify the exact jacking points.

Place the jack securely under the car at the designated jacking point. Ensure that the jack is centred and stable before proceeding. Now, you can start to lift the car slowly and deliberately. Use the jack handle to pump the jack and raise the vehicle to the desired height. Make sure to follow the instructions provided by the manufacturer of your specific jack model. It is important to work at a steady pace and avoid lifting the car too quickly, as this can compromise safety and stability.

Once you have achieved the desired height, securely place the jack stands in the appropriate positions to support the vehicle. Jack stands will provide a stable base for your Mustang while you work underneath it. Ensure that the jack stands are rated for the weight of your car and are placed on a level surface. Now, you can carefully lower your Mustang onto the jack stands. Again, refer to the jack stand manufacturer's instructions for proper use and safety guidelines.

After lowering the car onto the jack stands, it is essential to ensure that the vehicle is securely supported and will not shift or move during the fuel sending unit replacement process. You can do this by gently rocking the car to verify that it is stable and firmly in place. Once you have confirmed the stability of the vehicle, you can proceed with the next steps of the fuel sending unit replacement, such as draining the fuel and disconnecting the sending unit. Remember to always exercise caution when working underneath a lifted car, and ensure that the vehicle is securely supported at all times.

Drain the fuel

Before you begin, it's important to drain the fuel tank completely. This can be done in a couple of ways. If your Mustang is drivable, the best way to do this is to simply take it for a drive until the tank is empty. If it's not in a drivable condition, you can drain the fuel from the sending unit or, if your tank has one, through the drain plug. Keep a pan handy to collect any fuel that may come out when you disconnect the sending unit.

Disconnect the sending unit

Once the fuel tank is empty, you can begin the process of removing the old fuel sending unit. First, pull the sending unit wire off the stud. Then, disconnect the hose from the fuel tank. Keep your pan close by, as there may still be some fuel left in the tank that could leak out.

Clear out your trunk

Now that the sending unit is disconnected, move to the trunk of your Mustang and clear out any items or trim that may be in the way. You'll need to access the fuel tank, so make sure you have enough space to work comfortably.

Remove the trunk bolts

With the trunk cleared out, locate the bolts holding the fuel tank in place and remove them. In most cases, there should be twelve bolts that need to be removed.

Loosen the filler pipe clamps

The next step is to loosen the clamps that hold the filler pipe to the filler pipe seal. There are usually two screws holding these clamps in place. Loosen these screws and then remove the clamps.

Remove the filler pipe hardware

To remove the filler pipe, you'll first need to take off the gas cap. Then, locate the bolts holding the filler pipe in place. There should be four bolts underneath the gas cap and one on the inside of the trunk. Remove these bolts to detach the filler pipe.

At this point, you've completed the disassembly process and are ready to install the new fuel sending unit. Remember to test the new unit before installing it to ensure it's functioning properly.

Disconnect the sending unit

Disconnecting the sending unit is a crucial step in replacing the fuel tank of a 1965 Mustang. Here is a detailed, step-by-step guide on how to do it:

First, pull the sending unit wire off the stud. This will disconnect the electrical connection to the fuel gauge, which indicates the amount of fuel in the tank. It's important to be gentle during this step to avoid damaging the wire.

Next, you'll want to disconnect the hose from the fuel tank. This may involve cutting or removing the original clamp, as some models use a one-time crimp-clamp. Be prepared for any remaining fuel to come out of the hose and have a pan ready to collect it.

At this point, the sending unit should be successfully disconnected. You can now proceed to remove the fuel tank from the vehicle by following the subsequent steps in the replacement procedure.

It is important to note that working with fuel and vehicle components can be dangerous. Ensure you are in a well-ventilated area, and take the necessary precautions to avoid any fire hazards. Always refer to the vehicle's manual or seek professional assistance if you are unsure about any steps in the process.

Additionally, the tools required for this procedure may vary depending on the specific model of your 1965 Mustang and the replacement parts used. Refer to the replacement part's instructions and your vehicle's manual for a comprehensive list of tools and steps required for the entire fuel tank replacement procedure.

Clear out your trunk

Once you've drained the fuel tank, you'll need to move to the trunk of your Mustang and clear out any items or trim to allow you access to the fuel tank. This is an important step, as it will give you the space you need to work on removing and replacing the fuel tank. Make sure to set aside any personal belongings and move any loose items to a safe place, so they don't get damaged during the replacement process.

Now that the trunk is cleared out, you'll be able to access the fuel tank and begin the process of removing it. This involves removing the bolts that hold the tank in place. In the case of the 1965 Mustang, there are twelve bolts that need to be removed. It's important to be systematic when removing these bolts, so you don't lose track of which bolts go where. You may want to refer to a diagram or manual to make sure you're removing the correct bolts and following the proper procedure for your specific model of Mustang.

With the bolts removed, you can now start to loosen the filler pipe clamps. These are the clamps that hold the filler pipe to the filler pipe seal. Loosen the two screws on each clamp, and then remove the clamps themselves. Again, be careful not to lose any screws or parts during this process, as it's important to keep everything organized for reassembly.

At this point, you'll need to remove the filler pipe hardware. Start by taking off the gas cap and locating the bolts that hold the filler pipe in place. There should be four bolts underneath the gas cap and one on the inside of the trunk. Remove these bolts and set them aside, making sure to keep them together so you can easily access them when it's time to reinstall the filler pipe.

Now, you can remove the filler pipe itself. Gently pull it off the tank while rotating the assembly. It should slide off without too much force. Then, twist the hose off the pipe and remove the filler pipe completely. Remember that you'll be reusing the filler pipe when installing the new fuel tank, but you'll be provided with a new filler pipe hose and gasket, so you can discard the old ones.

Remove trunk bolts

To remove the trunk bolts of a 1965 Mustang to replace the fuel sending unit, follow these steps:

First, ensure you have the necessary tools, including a flat-head screwdriver, a Phillips-head screwdriver, a jack, and jack stands. You will also need a pry bar, a scraper, and a hammer.

Next, drain the fuel tank completely. You can do this through the sending unit or, if your tank has one, the drain plug. Once the tank is empty, disconnect the sending unit by removing the wire from the stud and detaching the hose.

Now, move to the trunk and clear any items or trim that may obstruct access to the fuel tank. Then, locate and remove the twelve bolts holding the tank in place. With the bolts removed, loosen the two screws on the clamps securing the filler pipe to the filler pipe seal, and remove the clamps.

At this point, you can remove the filler pipe hardware. Start by taking off the gas cap, then remove the five bolts holding the filler pipe: four bolts underneath the gas cap and one inside the trunk. With the bolts removed, pull the filler pipe off the tank by rotating the assembly and twisting the hose off the pipe.

You will reuse the filler pipe when installing the new kit, but you can dispose of the original filler pipe hose and gasket.

Frequently asked questions