Corvette C2 Fuel Sending Unit: Diy Replacement Guide

If the fuel gauge on your 1963-1967 C2 Corvette is faulty, it's likely that the fuel tank sending unit is to blame. These units are constantly in fuel, moving, and subjected to vibrations, so they often fail and need to be replaced. The good news is that replacing the fuel tank sending unit is a relatively easy job that can be done by anyone with a few good hand tools and a few hours to spare. Corvette Parts, Inc. offers all the parts you'll need to complete the job, and with a little know-how, you can have your fuel gauge working correctly again in no time.

Corvette C2 Fuel Sending Unit Replacement

Parts needed for replacement

To replace the fuel sending unit in a Corvette C2, you will need the following parts:

• A replacement fuel sending unit that meets OEM specifications.
• A fuel tank sending unit removal tool.
• Gaskets and other hardware, such as strainers and bolts.
• A new O-ring for the fuel pump.
• A new fuel filter sock (optional but recommended).

It is also worth noting that you will need to drain the fuel tank before beginning the replacement process. This can be done by siphoning the fuel out or by detaching the fuel lines and allowing the fuel to drain into a suitable container.

Additionally, while it is not necessary to replace the entire fuel pump assembly, it is often easier to do so, especially if your car has high mileage. In this case, you would also need a replacement fuel pump assembly.

Disconnecting the battery

To disconnect the battery, first locate the battery in your Corvette. It is usually found in the engine bay, near the front of the car. Once you have located the battery, you will need to disconnect the negative terminal first. This is usually indicated by a black cable and a "-" symbol. Use a wrench or socket to loosen the nut that holds the cable to the terminal. Be careful not to let the wrench touch any other metal parts, as this could cause a short circuit.

After the negative terminal is disconnected, move on to the positive terminal, which is usually indicated by a red cable and a "+" symbol. Again, use a wrench or socket to loosen the nut and disconnect the cable. With both cables disconnected, you can now remove the battery from the car. Place it in a safe location, away from any sparks or flames.

Now that the battery is disconnected, you can proceed with the next steps of replacing the fuel sending unit. These steps include removing the spare tire and carrier support, cutting the rubber hose that goes from the sending unit to the frame fuel line, and unscrewing the locking ring. Remember to always work safely and refer to a shop manual for your car if you are unsure about any steps.

Removing the spare tire

To remove the spare tire from a C2 Corvette, you will first need to unlock the spare tire lock. This will be located under the rear bumper on the driver's side. Once the lock is removed, you can then use a jack or lug wrench to loosen the hex head bolt that is underneath. With the bolt loosened, you can then use the jack handle to leverage the tub up and off the retainer bolt. Lower the tire and tub to the ground and then remove the tire from the tub.

If you are looking to access the build sheet on top of the original gas tank, be aware that you will need to do more than just remove the spare tire. It is not recommended to drop the fuel tank just to access the build sheet. Instead, you can try looking for it by pulling back the rubber "boot" around the gas cap and shining a flashlight into the tank.

If you are trying to access the fuel sending unit, you will need to remove the spare tire and tub to see where the sender is located at the bottom of the tank. It is a good idea to drain the tank first, as removing the sending unit will leave a large hole in the bottom of the gas tank.

Draining the fuel tank

Before you start the process of replacing the fuel sending unit on your Corvette C2, it is important to drain the fuel tank. This is a crucial step for two reasons. Firstly, it is much easier to work with a tank that has less fuel, and secondly, when you remove the sending unit, you are left with a large hole in the bottom of the gas tank. Here is a step-by-step guide on how to drain the fuel tank:

Step 1: Disconnect the battery

It is always a good idea to disconnect the battery before performing any maintenance or repair work on your Corvette. This will prevent any accidental electrical issues and ensure your safety.

Step 2: Remove the spare tire and carrier support

The next step is to remove the spare tire and carrier support from the car. This will give you access to the fuel tank and the sending unit. Make sure you have a safe and clear workspace to perform this step.

Step 3: Cut the rubber hose

Now, carefully cut the rubber hose that connects the sending unit to the frame fuel line. It is recommended to use a new hose instead of reusing the old one, as it is a safety hazard. Place a 3/8 bolt into the frame line end and let the remaining fuel drain into a suitable fuel drain pan.

Step 4: Drain the fuel

At this stage, you should have a significant amount of fuel drained into your pan. Make sure you are working in a well-ventilated area and always wear eye protection. It is also a good idea to have a fire extinguisher nearby as a safety precaution.

Step 5: Use a sending unit locking ring removal tool

Once the fuel is drained, you can use a sending unit locking ring removal tool to unscrew the locking ring. This is a much better option than using a hammer and screwdriver, which was a common method in the past. Place the tool on the locking ring tabs and turn it to loosen the ring.

Step 6: Clean the sending unit contacts

Before removing the sending unit, it is a good idea to clean the contacts for better performance. Use a small screwdriver to release the spade connector from its retainer and slide it out. Clean the contact point thoroughly and then slide the connector back into place.

By following these steps, you will have successfully drained the fuel tank and prepared it for the next steps in the fuel sending unit replacement process. Remember to always put your safety first and work in a well-ventilated area when dealing with fuel.

Installing the new sending unit

First, disconnect the battery. Then, remove the spare tire and carrier support from the car. Now, remove the spare tire carrier by unscrewing the carrier latch support assembly and four additional bolts. Cut the rubber hose that goes from the sending unit to the frame fuel line in half and put a 3/8 bolt into the frame line end. Let the remaining fuel drain into your drain pan.

Next, take the Corvette sending unit locking ring removal tool and place it on the locking ring tabs to unscrew the ring. Clean the sending unit contacts. To remove the spade connector from its retainer, slip a small screwdriver into the receiving end, release the spade retainer tab, and slide the spade connector out of the back of the retainer. You can now clean the contact point. Slide the connector back into the retainer and lock it into place.

Take a new gas hose and, using the old hose as a guide, cut a new length of hose. It is also a good idea to replace the fuel hose clamps. Before you install the new sending unit, compare it to the old unit to make sure the bends and connections are where they should be.

Now, connect the sending unit wires to the sending unit and re-connect the battery. Have a friend sit in the car and turn the ignition on to watch the fuel gauge. Holding the sending unit in your hand, slowly move the float on the unit. If everything is connected correctly, the dash needle should move in accordance with the float. If it does, you are ready to reinstall the sending unit. If not, the problem lies with the wiring or the dash gauge. Remember to disconnect the sending unit wires and the battery before you continue.

Carefully slide the sending unit into the fuel tank, making sure that you place the sending unit gasket onto the sending unit before you install it. When the sending unit and gasket are in place, slide the locking ring down over the sending unit tabs. Then, take the locking ring wrench and tighten the locking ring until the locking tabs rest against the tank stops. Now, install the new fuel hose and clamps, and re-connect the sending unit wiring. Re-install the spare tire carrier assembly, re-connect the battery, and replace the fuel.

Frequently asked questions