How to Replace a Sender Unit Boat Gas

When your boat's fuel gauge stops working, it may be the gauge, but more likely it's the mechanical sender in the gas tank. Taking the sender out of the tank means there will be a hole -- as large as 8 inches across -- in the tank, so of course this is a project best undertaken when the tank is empty, whether you run it nearly dry or after you've emptied the tank of its fuel.

Things You'll Need

  • Sender
  • 1/4-inch socket
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Instructions

    • 1

      Remove the screws holding the old sender in place. Pull the sender and float from the tank and use a paint scraper to remove any gasket material that remains around the hole in the tank.

    • 2

      Connect the pink sender wire to the terminal on the back of the fuel gauge that's marked "Sender" or "S." Connect the black sender wire to the boat's common ground.

    • 3

      Insert the float through the gasket provided with the sender. Move the gasket up the float arm to the sender. Align the bolt holes in the sender with the bolt holes in the gasket.

    • 4

      Push the float through the hole in the tank. If you have problems getting the float into the tank, turn the sender and float upside-down. Push the float into the tank and turn the sender right-side up.

    • 5

      Move the sender to align the bolt holes in the gasket and sender with the bolt holes around the hole in the tank for the sender. Thread the self-tapping bolts that came with the sender through the holes. Tighten the bolts with a 1/4-inch socket.