Fuel level sender replacement tip, W126
 

Finally got around to replace the fuel level sender. The reserve light was always on. Took out the back seat and pop open the round rubber plug. Here is this sender which requires a 46mm socket to remove it. Tried using channel lock and boy is it on tight, and the small opening prevent applying leverage.

Here is the trick:
Lift the rear deck just enough to slip out the black plastic box for the first aid kit. Now I can use the channel lock through the box openning to remove it. Easy job if done this way.

NICE!

I am getting the windows tinted for a discount so I am removing the rear deck for the guy. My light NEVER comes on, so that was on my list of repairs. I will be doing this while the tint "drys" "sets" "ages" "seals" "CURES", thats the word I was looking for.

Thanks again for the tip.

Just for the info, I got a 46 mm socket from Enco, along with a 3/4 to 1/2 adaptor for less than $20.00. Was able to clean my sending unit and all is well. Thayer, cleaning it might just cause the light to work again. Also, I see your location is Mt. Airy. I was just there this morning, early afternoon.

Here's a better trick:

Go out and purchase a 1 13/16 socket.........the cheapest one you can find..........and do the job correctly.

What would be a good solvent to soak the level sender for cleaning? Gasoline? Alchahol?

Toilet wrench works very well on the sender. You can use it on toilets too. I used carb cleaner--just sprayed it on.

Here is a good link.
http://www.peachparts.com/shopforum/diesel-discussion/189366-fuel-sender-85-300d-cleaned-pics.html

I have cleaned 4 of them. used the 1 13/16" socket with the 3/4" adaptor to drop it down to 3/8" to remove the sender. It is best to wait until you are down to the reserve, then there isn't so much fuel to drain out of the tube lifting it out of the tank. but if the light doesn't work, hmmm, have to let it drain out of the little hole. also have some rags and a pan to get under it.

I used brake cleaner in a spray can and a little brush to loosen up the gunk in the wires and rod. be very careful with the thin little wires. spray some cleaner, gas, paint thinner on a rag, and run it through the tube to clean out any gunk and the black stuff that discolors the aluminum. then spray brake cleaner down the tube and let air dry.

If you need one for a replacement, PNP charges $22 for one.

This 1 13/16" socket also works for the fuel strainer in the bottom of the tank. my socket is beveled on the inside edge, so doesn't have enough meat to catch the edge of the strainer or sender. I need to cut it in 1/2 and leave it flat across the opening. don't know if all are like this or not.

Charlie

Ours was beveled too, we ended up just sawing it in half so it was flat like the factory tool, works perfectly.

OK, found this thread where Lucky Eddie cut one down for a guy.
http://www.peachparts.com/shopforum/2119776-post30.html

Notice how it is flat instead of beveled.

Charlie