Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2005 Chevrolet SSR StandardFACTORY OEM SERVICE PROCEDURE
Removal Procedure
- Remove the fuel tank. Refer to Fuel Tank Replacement .
- Remove all dirt and debris from the area around the fuel sender assembly and the fuel tank.
- Remove the fuel lines from the sender assembly. Refer to Fuel Hose/Pipes Assembly Replacement .
- Using the J 44402 , remove the retaining ring for the fuel sender assembly. See Special Tools .
- Remove the fuel sender assembly and seal.
- Remove the seal from the fuel tank. Discard the seal.
CAUTION:
Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container.
Factory Service Tools
Use the Manual With the Right Hardware
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.
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