Replacing Oil Level SendingUnit Gasket on Tank

[IAN]

Do I need to do anything special to the cork gasket when replacing it to keep it from leaking?

thanks,
Ian

[carmad]

Simple replacement, do not overtighten the nuts.

[Jim Sims]

I lightly coat the cork gasket with Curil-T, replace the aluminum washers under the nuts if damaged (crushed or cupped from overtightening - usually the first reaction to a leak is to retighten the nuts which often overtightens them). Clean electrical connectors and coat contact surfaces with dielectric silicone grease before reconnecting. Jim

[911SCfanatic]

Jim, do you no the part no. for the small washers? Does PP carry them? Now that you mention the cupped washers, I remember when I replaced my fuel tank gasket that the washers were cupped.

By the way, do you know where I can get a torque wrench that will be accurate to that low of torque? Right now, I'm using my Craftsman 3/8 drive torque wrench, but I have to turn the adjustment member to below where the readings start so its probably not that accurate.

[IROC]

IMHO, the exact torque on something like these fasteners is not critical. The critical thing is to not over tighten them. Alot of the problems (leaks) with gasketed joints comes from over torquing the fasteners.

Mike

[Jess]

Instead of the cork gasket, which as you have seen will eventually leak, you can use the rubber one that is meant to go on the gas tank sender.

It is the exact same size and bolt pattern but is made from a more durable material.

Jess

[Jim Sims]

Have alum. washer part number at home; will post tonight. Jim

[KTL]

The washer part number is 900 025 003 30 It's a M5 washer (5.3mm I.D. I believe) Pelican carries them, but they're a special order OEM part. I assume it'll take a few days for Pelican to get them.

I did the same things Jim Sims described. It's a good idea to coat the cork gasket with something because oil and heat make it brittle over the years. Mine was like an overcooked french fry when I removed it. I used the green Curil T goop, but you could also use Permatex Copper Gasket Spray which is available at most any local parts store. Got mine at Pep BoyZ.

Tighten the nuts on the sender just until you feel the cork gasket starting to smush. I checked my tightening with a Snap-On 0-300 inch-pound dial torque wrench and I don't think I could even get the nuts to torque to 50 in-lbs (less than 4 ft-lbs, THIS IS VERY LIGHT). So you're going to think they're not tight enough. Don't worry. Just make 'em snug against the sender plate without squishing the daylights out of the cork gasket and the fragile washers.

The rubber gasket from the fuel tank sender is a good thing to know! Wonder why Porsche didn't make 'em both rubber?