Any tips on installing a fuel level sensor assembly in a tight space?

Yes, they have rubber. But moisture gets in there and the aluminum corrodes over time.

 

Now for an ignorant question...
I know a lot of people have posted about flashpoint for diesel being somewhere around 125 - 250° (depending on who thinks they know on any given day). My tanks are well over 100° after running all day (return fuel is VERY warm). Would. It. Be. Possible to braze/fill the corroded spots on the tank to take the pitting out and make them smoooth again?

 

Use a cutoff tail from a ratchet strap for a tank pad. On a pete you cant even tell theyre in there. Theyll rub a hole thru with no pads.

We pump ours off into a drum or two everytime ol rooster stuffs a tank in. He shoulda named himself turkey.

 

Mine has the rubber sleeves, but still had a bunch of white corrosion, I wasn’t expecting that. 16 yrs worth, even some deep pitting. If it weren’t for the pitting, I would have just used silicone. But I wanted to stop the corrosion, the grease will destroy the rubber eventually, not in my lifetime though. Ive seen others get a Pinhole leak under a strap a couple times.Depending on where it’s located, I might cut a hole in the floor, especially if it’s under the bunk.Some Cadillacs, to change the fuel pump, you take the back seat out, there’s an access plate. Other GMs don’t have one. So you have make your own. Beats dropping an old rusty fuel tank.

 

Assuming there is no actual fuel leaking you could do that. I have had patches tig welded on a tank before and no issues. If there is pitting you can use JB Weld, the fast setting one to fill the holes. Just clean them with a wire brush and then brake parts cleaner real good. I have done this as well with great results.

 

Here is what you do. Drop it off at your local mechanic, go home and do whatever the #### makes you happy, then go pick it up and get back to the money.

 

Does your dash have a gallons burnt display? On a cascadia I drove the gauge was so inaccurate I just reset the fuel consumed every fill up .. after a few tanks you can judge how close it is to actual amount used.

 

If you've got a couple inches to swing a hammer, dimple the metal from underneath with a pointy screw or nail. Locating problem solved.