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Thread: YJ fuel sending unit access hole

  1. #1
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    YJ fuel sending unit access hole

    Jeeps should have an access port to the fuel tank. They don't. Here's how to fix that.

    From the lip of the gate, measure up and mark at 6" and 14"


    From the left wheel tub, measure and mark at 14" and 22"


    Mark out your access hole

    Using a thin wheel, I cut mine out. You can see in this picture how close 6" is to the support bar. I'd recommend going to 5 3/4" so you're sure you're all the way through.


    Et voila!


    For clarity, where to clip the tape measure.


    For clarity, where to push up the tape measure against.


    Good size window without getting stupid. I'd strongly recommend you find a way to reattach that support in such a way as you can remove it to remove the pump, but that's beyond the scope of this thread.



    No more worries about accessing the sending unit again.
    ....-Noltz
    '91 Frankenheep Edition. 4.0, 4" BDS, Richmond 8.8, 35" KM2's, Titan 12k, ... gone.
    '95 4Runner SR5. Air-Lift bags, OBA & 8K Winch, DD... gone.

  2. #2
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    nice mod.
    my jeep came factory with one of those access panels... lol

  3. #3
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    Why the access panel? Are jeeps prone to have issues with sending units? I have a 95 YJ and haven't had an issue yet... knock on wood!

  4. #4
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    i made my own... not sure if they are prone to it, but i know they arent fun to drop....
    If its a mechanical device i can fix it

  5. #5
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    Well I was DAMN glad I did it... pump died yesterday on the way to the shop! Changed it in a parking lot....

  6. #6
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    I for one am going to make use of this post, thanks Noltz
    ps, also have an idea for re-establishing the strength of the support, will post if it works out....won't if it don't.
    special talent..to screw things up at the push of a button.

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    nice idea and not a bad thing to do soon ... im taking the tub off to do some work on the frane anyways! thanks for the post!

  8. #8
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    its hard to tell from the pics but how much in the way is that support bar? if you left it there would removing the pump still be do-able? also how do you plan to patch the hole? otherwise thanks for the measurements! something ive always thought about doing... had to drop the tank on both yj's in a weekend to fix various problems that this could have solved easier.

  9. #9
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    I'll get more pics today for ya Tazz. The bar covers about 2" of the pump. I've read you can bend the lip and sneak the pump out. I don't have first hand experience with that. With this, I can pull the sending unit out clean, rotate it and actually hang it out the tail gate so no drips on the jeep.

    As for patching I intend to get a piece of thin checker plate and bolt it down. For now I've just dropped the OE steel back in place.

  10. #10
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    Noltz
    did you have your tank out when you did this ?
    I am wondering about possible dangers of sparks & fuel vapours etc.

  11. #11
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    Why don't you just drop the tank? It's really not that hard? I am pretty sure there isn't a hatch there for a reason. I defiantly wouldn't want to get doused with gas if rear ended!! A couple of sheet metal screws will be nowhere near as strong as solid metal. I won't be doing this to my jeep.
    Now i have a JEEP I am getting good at fixing things lol

  12. #12
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    Thanks for this info....

    Curious as to how much space between tank and floor? Can I cut the hole without taking out the tank?
    My latest project... Collection of Parts

    Other stuff... Building a doubler, D300 Flip kit

    Quote Originally Posted by Deadman 94 xj View Post
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    ебут раком

  13. #13
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    i cut mine with the tank inplace.... i have a 1 inch body lift though.... i wouldnt recomend if you have a fuel leak to do it with the tank in there.... i did have mt hole sealed up with the peice i cut out and some silicone but after i had to use it a few times now i have a big peice of rubber covering it now.
    and i always carry a trail spare fuel pump just in case

  14. #14
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    Quote Originally Posted by akafred View Post
    Why don't you just drop the tank? It's really not that hard? I am pretty sure there isn't a hatch there for a reason. I defiantly wouldn't want to get doused with gas if rear ended!! A couple of sheet metal screws will be nowhere near as strong as solid metal. I won't be doing this to my jeep.
    I prefer to drop the tank, then I can get all the 20 year old crap out of the tank that could plug up a new pump.

  15. #15
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    Finished this up yesterday.

    Did it with the tank in place and took my sweet time so to not cut anything under the floor.

    Also just cut some 20g and put it as a lid for the access panel.




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