The new fuel sending unit is too tall to fit in the tank? Anyone else have this problem, and how did you correct it?

quote Originally posted by Wayne Renninger: The new fuel sending unit is too tall to fit in the tank? Anyone else have this problem, and how did you correct it?

picture. they may have sent you the wrong year one

I called the Fiero store, they said they sold hundreds with no problems, I measured the old unit ,about 1/2 '' shorter. The Fiero store says the only differance is between 4 and 6 cyl wiring? A freind bought the one from Rodney Dickman , is 1/2' shorter and comes complete with evrything about $100 cheaper. I plan to cut the stainless tube and reweld the mount .

quote Originally posted by Wayne Renninger: I called the Fiero store, they said they sold hundreds with no problems, I measured the old unit ,about 1/2 '' shorter. The Fiero store says the only differance is between 4 and 6 cyl wiring? A freind bought the one from Rodney Dickman , is 1/2' shorter and comes complete with evrything about $100 cheaper. I plan to cut the stainless tube and reweld the mount .

unfortunately they lied to you as they have been to me recently.
they did sell a 87-88 unit to you or decided to let their manufacturing get away with making parts wrong again (so far its 4 speed v6 cables, all the relays for the early headlights, the entire bushing kit for the 88, the upper balljoints for a 88 actually don't fit and are in full contact with the frame at full droop and mostly bottomed out. etc.)
I wish for the premium they charge they would actually test fit the parts coming off assembly semi regularly for proper fitment

The early Fiero gas tanks were ten gallons. The later ones were larger at 12 gallons. Could that be the difference in the sender that you're using. There were also reports of the float sticking up on some of the Fiero store units. I would make sure that the float sits exactly as it did on the unit you removed.

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quote Originally posted by Dennis LaGrua: The early Fiero gas tanks were ten gallons. The later ones were larger at 12 gallons. Could that be the difference in the sender that you're using.

Maybe.

The two tanks are roughly the same dimensions but later tank has different fill port plumbing to fill the tank w/ more liquid fuel & move most of the "free space" that allows liquid to expand safely to the aux tank under the body on the right side of car to allow 11.x fuel cap.

Minor difference in just location @ the end in the tank of the big Liquid Fill line &/or Fill Vent line can set max liquid before Station Pump nozzles trips off.

Related ⚠️ Warning: If the pump assembly fails to seal, more so on 87-88 tanks, then Very Easy to have Gas on the pavement when you fill the tank. Worse if you try to "stuff" the tank even a little after the station nozzle trips auto shutoff. That's how I "found" the tiny leak in https://www.fiero.nl/forum/F.../HTML/146198.html#p4 because 87-88 tanks next to zero "free space" & pin hole size leaked enough to stay put to allow evaporation before doing anything.

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The new sending unit is vastly better quality (in my opinion) than the old one; however, it is a little bit longer than the original 84-86. This is not a huge problem, really... you just need to bend the bottom of the sending unit slightly so that it doesn't push against the bottom of the tank. My daughter did this for her 1985 Fiero, and it fits just fine.