S4 fuel Sender Replacement Nut Installation

[2_wheeler]

I have an 01 S4 Monster...bought an alloy fuel sender nut my plastic one broke...how do I get the plug apart to get the nut on the sender?  Do I have to resort to cutting the wires?  Thanks in advance.

[Speeddog]

You don't have to cut wires.

It's a bit fiddly to get the connectors out of the shell.

[brad black]

dental picks are good tools to have for this.  and patience, for the first few times.  and not an explosive, chucking shit around in frustration or smashing it up with a hammer temper.  my dad had one of them.  i think he's over it now, but i watched him smash a whole load of stuff up when i was younger.  just cussin' and hammerin'.

[koko64]

Had a mate that chopped up his mower with an axe when it wouldn't start. New mower.

[2_wheeler]

No smashing yet...lol...their are 4 pins and two plastic pin looking tabs (?) I read a brief blurb online about removing the red plate the pins go thru, and pushing a tab that is accessible once the red plate is out of the way...It sounds like you guys have done this... tips to removing the red plate once I have "dental equipment".  I am trying NOT to break it.  Thanks.

[brad black]

one of my dental picks has a right angle bend on it, with the hook about 3mm long.  it goes thru one of the holes i the middle of the red piece, and hooks it out.  the red piece comes straight out, but the emphasis is on straight.  try to lever one side them the other and it'll jam.

then you just lift the little tab holding each terminal in and slide them out.  make a note of where they go.  there are # on the connector 1 to 4.  use a torch to have a good look for the tabs.  should be easy.

[brad black]

Had a mate that chopped up his mower with an axe when it wouldn't start. New mower.

problem solved.

[2_wheeler]

Big Thanks after getting my "dental tools" I was able to get it all apart...Funniest part is that the nut will not fit over the green washer...maybe nut is too small, so different years have different sizes ??...the plastic and metal look the same...I thought I measured but must have been off; or nut is.

[Speeddog]

Check to see if the nut threads onto the tank fitting.

Likely it does, then just persuade the green rubber washer to go down into the nut.

[ducpainter]

 little grease on the o-ring will help...a lot.