Luis_M

I recently had to remove the fuel level sender unit from my 81 Euro S (actually my wife's!). The shop that installed the replacement some time ago must have used a large wrench, which left a number of dings in the plastic nut visible in the picture. I hacked together the following substitute for the special pin wrench tool out of a piece of aluminum and some galvanized wire.

I bent a 12" x 1/2" x 1/8" flat aluminum bar for the hardware store in to the rough U-shape and then "tightened" it with some galvanized wire near the open end until there was a snug fit at the nut. The sides of the bar provided broad contact against the plastic ridges on the nut. Although it certainly isn't pretty and there was some deformation of my makeshift tool under torque, it was actually pretty easy to remove and later reinstall the nut with this, and without any further damage to the plastic.

Luis

jon928se

Top marks for ingenuity

Neccessity being the mother of invention and all that. I think I used a piece of hardwood and a mallet - somewhat cruder.

Rob Edwards

I used a pair of oil filter pliers that opens to 3 or 4 inches. Munged up the teeth on the ring a little, but not too bad.

jorj7

Luis,

Kind'a fun title, coat hanger and bent aluminum bar as a "Special Tool" substitute....

tmpusfugit

I tried a tool somewhat similar to the one Luis has created, I tried the wood block routine, I pulled the tank and tried very large channel lock pliers, and also tried an oil filter wrench, all to no avail. I finally made up the item in the photos. A quick trip to Home Depot for a PCV soil pipe fitting, I then turned the inside diameter to that of the ring retainer. I then milled 12 "slots" using a 5/8" mill, and cut another slot for clearance around the return tube, and finally drilled a 1/2" hole to use a 3/8" ratchet extension for twisting force on the ring clamp. It took me about 20 minutes to fabricate this "tool" and it worked immediately, and it worked very well. I am not certain how the PO ever tightened the ring as tight as it was....it would not yield to the other methods I tried. I expected to find Locktite on the threads....but did not....

928mac

I use the large tongue and groove pliers
http://www.tongue-and-groovepliers01s.co.cc/

jpitman2

I just cross two long screwdrivers - right over left to undo, left over right to tighten. But I like the idea of the large PVC item....might make one of those. I made a diff filler plug wrench by welding a suitable bolt to a piece of 1-1/4x1/4 steel plate.
jp 83 Euro S AT 52k

Tom M'Guinn

Puling up this old thread to share a tool I found that works very well on this. It's an adjustable oil filter wrench from Sears and is only 12.99. It has a hex nut and 3/8 drive on top so you can torque to spec too. Works like a champ with no scratching or fuss...

http://www.sears.com/shc/s/p_10153_12605_02820523000P

ROG100

Tom,
Thanks for sharing - off to Sears.
Roger

Pfc. Parts

Tom you're a lifesaver, thanks. I couldn't find the Sears part but I found its logical (and hopefully physical) equivalent on Amazon with free 2 day Prime shipping here:


I should have it on Wednesday, I post a report on how it works.

Thanks again,
Scott

69gaugeman

+1

Mongo

I gave up on my cap for the sender.

My sensor completely needs replacing too.

Jadz928

+2

thanks for sharing

Mrmerlin

Great ideas on tool making/ substituting yous guys!

FWIW to reinstall the sender nut make sure to soak it in very hot water for 5 minutes then install it,
I suggest to use some Dow Corning 111 on the O ring this will keep it soft

danglerb

Similar looking 3 jaw at Harbor Fright, $10, thinking Lisle makes one too.