8 captured repliesDiscussion pagination complete · Source accounts, not a confirmed diagnosis
THIS DISCUSSION / SOURCE-DERIVED OVERVIEW
Discussion summary
YOUR RESEARCHRepairing a fuel sending unit?
Leading reported evidence
Replace by an independent shop
Performed · outcome unconfirmed
No successful repair reported for this finding.
0
Reported fixes
0
Unsuccessful attempts
1
Discussions
Read evidence and context
Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.
Discussions that performed work without a confirmed outcome
1
0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Leading evidence: 'Replace by an independent shop' (no explicit attributable resolution; this is a reported action or suggestion). Across 1 matching discussions, the most frequently mentioned possible cause is 'float shaft rod got bent' (1 discussions; 0 report identifying it and 1 suggest it). The most frequently discussed action is 'Check fuel tank level' (1 discussions). For that action, 0 discussions report a resolution and 0 report an unsuccessful attempt. No action has an explicit, attributable resolution report under the current rules. These are forum reports and suggestions, not a confirmed diagnosis.
Source reports, not a diagnosis or a success probability. Counts refer to discussions and can overlap.
Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.
Discussions that performed work without a confirmed outcome
1
0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Performed · outcome unconfirmed · Original poster
I replaced the O ring that seals the fuel neck to the tank.
Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.
Discussions that performed work without a confirmed outcome
1
0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Performed · outcome unconfirmed · Original poster
I also used the gas tank 2 part epoxy to re-seal around the tank filler. This solved my gas leak smell.
Outcome qualification: Negation, uncertainty or missing explicit repair resolution overrides the raw extraction signal.
float shaft rod got bent
Suggestion or failed attempt
No successful repair reported for this finding.
0
Identified cause
1
Suspected cause
0
Reported fixes
Read evidence and context
Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.
Discussions that suspect a cause
1
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0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Suspected cause
More than likely the float shaft rod got bent when pump/sending unit was removed/changed out.
Explicit resolution reports before identified causes, performed actions and suggestions. Within each level, matching component labels precede direct query mentions and inherited thread context; successful versus unsuccessful discussion counts, owner confirmations and independent discussion support determine order. This is not a probability of success.
Discussions that contain suggestions
1
0 original-poster resolution reports. Counts can overlap; they are not unique people or a success rate.
0 discussions have direct query context; 0 report a fix in that context. Other evidence may inherit the discussion’s subject.
Suggestion
So now you can gently bend the rod up very slightly and re-check fuel tank level on gauge for a empty reading.
Counts describe captured discussions, not unique people or a diagnosis. Author identities are not reliably stored. Exact duplicate evidence is counted once across matching discussions; one discussion counts at most once per action/state. Multiple repairs reported together remain a combination. Suggestions and failed attempts do not establish a fix. Matches cover whole discussions and can include related faults, model variants and incomplete threads.
8 eligible posts · 0 unverified posts · 1 discussions match the subject in their title or opening post.
Rennlist: 1 discussions
0 evidence records excluded for query context · 0 excluded by outcome qualification · 1 adjusted by outcome qualification.
0 acknowledgements have no verified action link; they do not establish a repair result.
Generation: 20261027T013556Z · outcome-qualification-6. Deterministic extraction; no AI model inference. How we use sources
Hey all, I've had a fuel smell when I fill up my tank on my 02 cabrio. Searching the forums and it seems like a hairline crack in the fuel sending unit is a common cause. It sounds like a pretty easy replacement. An hour or so. But the new part is near $900 and my current fuel pump shows no signs of improper operation.
Assuming I remove the top hat in my frunk and find this same type of hairline crack... Has anyone ever just dremeled & epoxy'd the hairline crack?
Photo from a previous thread for reference.
$707 at DE porsche or $165 for the uro part. I would probably get the uro part over fixiing what u have.
https://www.autohausaz.com/pn/163388...MaAsH9EALw_wcB
I don't know if you ever ordered the Uro fuel sending unit, but I don't think it fits an '02 Cabrio, I have an '02 Targa and I think we're stuck with eithe a brand new one from Porsche ($605) or a remanufactured one from Porsche ($500 after core return).
If you tried to fix yours i'd love to hear details.
Mine ended up not being cracked. I replaced the O ring that seals the fuel neck to the tank. I also used the gas tank 2 part epoxy to re-seal around the tank filler. This solved my gas leak smell. My sending unit turned out not to be cracked.
But... I've fixed countless things with epoxy. I honestly don't know why the top of this sending unit would be any different. Professional auto body repair techs can fix bumpers with epoxy.
If I were to do it, I would... Take a dremel and grind out a V where the crack is. As deep as you can go safely without going through. Then radius this out, soften the edge of the V by grinding progressively flatter area. Rough up all the surrounding plastic with 40 grit sand paper, or something similar. Clean with isopropyl alcohol or something similar. Then use the best 2-part epoxy that bonds to plastic. (I was a body tech for 10 years and highly trained by Toyota, BMW etc.)
According to Google, the plastic is POM,
check this out.
https://www.google.com/search?q=what...t=gws-wiz-serp
Had mine replaced by an independent shop. Ever since the miles calculator gas reserve is off by about 60 miles and analog gas gauge never drops below 1/4 tank even if empty. And when you fill the tank, the miles gas calculator and fuel gauge take over ten minutes to reach �correct values.� Indy shop too far away to take it back in. Do you think the new fuel sender was not calibrated and if so is it an easy fix?
Take the battery out, battery tray out, unscrew the tank hat retainer ring, and remove the tank hat with the sender unit. Detach any hoses/wires as needed to get the tank hat off and sender unit out.
With the tank hat out its easy to see the fuel level in your tank. Look, see how full it really is. For your problem you want the tank empty or as close to empty as possible.
With the sender unit out but wires plugged in and key on to let gauge work, manipulate the float up all the way and down all the way while someone watches the gauge for full movement. If the gauge does not read full when float is all the way up and empty when all the way down, the rheostat is faulty. Try to clean it off with some brake clean, very very lightly sand/brush/clean the rheostat coil wires and contact on float arm, don't go nuts here. When checking gauge might want to give it some time to 'normalize. You'll be able to see how it reacts when manipulating the sender manually and looking at the gauge to see its reaction time...
More than likely the float shaft rod got bent when pump/sending unit was removed/changed out. So now you can gently bend the rod up very slightly and re-check fuel tank level on gauge for a empty reading. Don't go over board here, bend the float rod a little at time till it just reads empty.
Above should calibrate tank gauge and everything associated with it just fine. If tank gauge still doesn't read correctly, time to go into PIWIS and let it do a calibration with a totally empty tank... follow piwis directions. I've done 2 996 senders like explained above and never needed piwis to calibrate gauge..
