Need help w/ Fuel Sender wiring on new tanks

[IFish4Tuna]

I just want to add to this thread so no one else makes same mistake....

My sender was indeed bad, and I replaced it with a reed sender from Moeller. The package came with 10 machine screws, and assorted other miscellaneous screws. The instructions for assembly are not very good. It does not say what the screws are for, yet at the top of page it says a Philips head screw driver is required. I could not make any sense of why I needed a Phillip's head screw driver nor why I would use the small Philips head screws.

More importantly, the reason for 10 machine screws is because they are offered with different threads. I did not realize that and began to insert 2 of the 5 screws before realizing the reason they were going in slowly was because the thread were wrong.

So match your old threads to your new screws.

 

[nightfighter]

Ugh. Not enjoying this read.... I have a tank replacement in my future on my 1993 209 Escape. Smelled fuel this weekend when getting up on a plane. Been having sending unit issues in the past. And have been out of the water for two years (knee replacement and follow up surgery). So poking around for info and ideas. I ordered Nigel Calder's Boatowner's Mechanical and Electrical Manual to help me with the wiring of the sending unit after getting Yamaha gauge back from GaugeSaver. Need to get eyes on top of the tank and see if it too has the "jelly" or obvious holes... Keep the info and pics coming. Guess I need to reach out to Grady for tank specs.

 

[seasick]

It sounds to me that your sender gasket might have a leak. When getting on plane, the gas runs backwards and will 'fill' the rear of the tank. Since the sender is back there, gas will up against it and if the seal is bad gas will seep out.
Yes your tank is old but that doesn't mean it is bad. Check around the sender flange for gas before you panic.