View Full Version : How to seal leaking fuel level sender?

01-18-2007, 02:41 PM
My 63 HawkGT is leaking around the circumference of the sender unit.
I have gasket paper to cut a new one, but wonder if it would be better
to use a paste like Form-a-Gasket that would better fill any voids.
Also, with the new gas additives, are there any gasket materials that stuff like
ethanol won't eat up?

1950 Champion Starlight
1963 Hawk GT
Santa Barbara

01-18-2007, 04:29 PM
Don't use the silicone sealer, a freind of mine used it and some of it wound up in the fuel filter. Enough to stop the car from running.


01-19-2007, 12:03 AM
About 2 years ago I made a new gasket with some thin cork gasket material. I did this over 2 years ago, still dry.

http://im1.shutterfly.com/procserv/47b6ce20b3127cce8d0e3b50356c00000000400CcNWTlozYsb http://im1.shutterfly.com/procserv/47b6dc03b3127cce970d7aafd15f00000010100CcNWTlozYsb
Studebaker Fever
60 Lark
51 Champion
Arnold, Missouri

01-19-2007, 12:32 AM
Nitrile rubber works for gaskets and fuel pump diaphragms. Not neoprene, which disintegrates or many silicones, which also seem to disintegrate.

Sheets of it are available at some auto parts stores - I'm in Canada, so I presume your NAPA or something will carry it. It comes in about 3 thicknesses.

Paul R

01-19-2007, 02:12 AM
Good timing, Richard. This is the next step for me to accomplish on my '63 GT. The cork gasket leaked when applied with no sealant. Would the nitrite material be applied with any sealant?

'23 Special Six,
'50 Business Champ,
'50 Starlight Champ,
'60 Lark droptop,
'63 GT

Blue 15G
01-19-2007, 07:46 AM
It shouldn't be necessary to use a sealer with the gasket. But if you must, the "old" style permatex is gas resistant (#s 1 and 2). Never use silicone sealers where they will contact gasoline.

01-19-2007, 09:22 AM
I cut out a new paper gasket and applied a little old style Permatex gasket sealant over one year ago and it has never leaked. Easy fix.

Mike with Speedster

01-19-2007, 09:39 AM
I've used cork. I think its thickness helps it deal with some of the irregularities you sometimes see. Also new brass washers for the screws is a good idea and Permatex can't hurt.

Tim K.
'64 R2 GT Hawk

01-19-2007, 09:57 AM
The new rubber gaskets I bought from one of our Studebaker parts vendors are really good, and less than $3.00. Just order one from http://www.studebakerparts.com . Maybe they can put it in a first class mail envelope to save postage. No reason to do it the hard way.

REVISION: I just now looked it up. It's a whopping $1.00! See the part here (https://www.studebakerparts.com/studebakerparts/parts/agora.cgi?cart_id=yE7klO.a7298*A40pC6&keywords=fuel+gasket&next=12), scroll to the bottom of the page.


1955 1/2 Ton Pickup
[i]The Red-Headed Amazon
Deep in the heart of Texas

01-19-2007, 12:39 PM
Thank you all for the suggestions. I will visit my NAPA today and first
try to get the nitrile rubber material or the cork gasket stuff. Probably
coat a little Permatex if the cork material.

1950 Champion Starlight
1963 Hawk GT
Santa Barbara

01-19-2007, 01:17 PM
Probably too expensive/hard to find these days, but the rubber tank sender gaskets for old style VW Beetles (like 1962 thru at least 1970, and maybe all the way up to the end of production)are just the right size. If I remember correctly, right screw holes and all.

chocolate turkey
01-20-2007, 10:06 AM
I just went through a perplexing gas leak situation with my 63 GT Hawk. I had replaced the original with a NAPA unit and had a leak at the sending unit. Replaced the gasket several times with several different materials. Still leaked. Found the leak to be the center plastic-to-metal joint of the sender, seeping profusely, not the sealing surface of the sender-to-tank. Watch for that one![8)]

Brian K. Curtis

01-20-2007, 11:09 AM
Chocolate Turkey:
What dash gauge are you using?
Do you know what range of ohm readings the NAPA unit puts out?
Is it for GM or Ford or Chrysler?
Does the gauge read accurately for full and empty?

62 GT Hawk