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Old 04-15-2005, 09:51 PM
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Join Date: Aug 2004
Posts: 124
Fixed my fuel level sender in a 300SD

Thought I'd post this for anyone who might need to do the same job, maybe save them some hassle...

First, take all the crap out of the backseat, instead of trying to work around it (like I did). Then there's a little lever on each side of the seat bottom the release it, then a small screw on either side near the bottom that come out to let you slide the seat back up and off the hooks at the top. Careful pulling it out or the little metal tab the screw was in will scratch the paint (doh!) Keep track of the screws for later!

Second, (Ignore this step if you have the right socket to fit the sender!) unscrew the latches to the compartments in the shelf, then you can work the shelf up and get the compartments out, but you don't need to take out the shelf out all the way. Be careful with how far you bend it or it will crack in the middle (doh! again) You need the drivers side one out to have a hole to reach through to use slipjoint pliers .

Third, pry off the black cap (it's about 4" in diameter, closer to the driver side near the top) and the sender is under that. Unplug the plug. I ended up using slip joint pliers to unscrew it, and it took every ounce of hand strength to do it without slipping and either gouging the sender or gashing my knuckles. If you have the right gigantic socket it will be a lot easier.

Fourth, pull out the sender, and realize that there is a tiny hole near the bottom of it the will be peeing out an invisible stream of fuel while you are holding it there thinking you'll just let a few drops drain off before moving it away from the opening (yet a third doh!). Have something ready to catch drips, and hold it so the last 4" or so are still down it the tank until it all drains.

Fifth, If you don't have the right tool, you'll need to sacrifice a screwdriver and cut a slot in the center of the blade to unscrew the nut at the bottom of the sender. I used a hacksaw, and be patient so you don't over do it. Then the plastic disk at the bottom unscrews by hand, and then the outer tube slides off. BE CAREFUL! The wires in there are hair thin! There are two thin wires the float rides on and a third wire that runs parallel to those. That's what my problem was, the third wire had snapped off where it solders to a tab near the bottom of the unit. Luckily it was still long enough that with a friend to push up on the tab and steady the unit, I was able to grab the wire gently with needlenose pliers and stretch it straight and re-solder it back.

Now the easy part, put it all back together! (minus the one screw you might lose if you don't take all the crap out of the back seat) Now I'll see if it actually works as the fuel drops, but it was encouraging to see the low fuel light go that had been stuck on go out. Wish I had the camera with me...

Good Luck!
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