How I rebuilt my Disco fuel sending unit.

[area51Rover]

Hi everyone, here's my story...


I bought a Disco for real cheap, I had to trailer it home cause it was puking gas from on top of the gas tank when running. (a little dangerous... Don't you think)

Had to cut the two hook loops from the back frame rails and drop down the rear sway bar to get the gas tank out. Once that was done I pulled the rear carpet etc to access the hatch. The screws that held it on were so badly rusted that there was no way they were going to come out so I hit one with a brass chisel and the whole plate fell out!

I'll post picks of the hatch fix after.

Put a Mic on the line and found some replacement line after removing the rusted off lines. Did some bends with the proper bending tool from princess auto and pressed them into the top of the plastic sending unit top. (had to dis-assemble the entire unit to do this)

Got new Clamps re-assembled the unit and reclamped the plastic gas lines, then after cleaning the entire tank... re-installed the unit.

Dirt buildup and water sitting on top of the tank was the cause of the rusted lines so I plan to coat the area with grease before I close the whole thing up.

Hope these photos may help someone in the future...

Visit my ebay stor if you have time, Untitled Document

Thanks

[pavel]

area51Rover: well done with your repair. Could you give more detail on the repair? A few more pictures of the repaired unit ready to install in the tank?
How did you seal the new tubes into the plastic or was the press fit good enough?

FYI: there is a guy in the UK who sells a cheap rebuild kit for the expensive fuel pump in your tank... you might end up needing to do that work too.

Cheers

Pavel in Vancouver

[area51Rover]

Hi Thanks for the positive comments,

I'm still plugging away at it, have some clamps and fittings on order to hook up these lines at the sending unit. It's not easy to find the proper fittings.
Seems the short brass fitting you see I have installed on the return line is not deep enough on the tread so I sourced out some steel ones that are the same length as the originals in the previous pictures.

The old hole was trimmed by a half inch and an oversized plate was fabbed.

Thanks for looking.

Rob