'97 400 DA Diesel fuel senders - How to get to them?

[Boat Guy]

'97 400 DA Diesel fuel senders - How to get to them and install - Answer

UPDATE: Fuel Sender Installation

Port: Location : In the port side cabinet opposite the helm where the ice maker is / or should be. If the ice maker is installed you need to unscrew the wood cabinet surrounding the ice maker. You need to unscrew and remove the carpeted panel attached to the right side of the ice maker cabinet. They are installed with long phillips head screws and they come out pretty easy. When the cabinet is loose, move it forward towards the bow. Once moved you will see a round approx. 6" cover. Remove the cover / access panel and the sender is directly below it.

Replacement: I replaced with Royce Industries Flexi-sensor P/N:1-0520-1134-0250 Desc:Flexi-Sensor, flange mounting, 30-240 ohms output, 25-inch length.

Installation: Installation is rather easy as there is plenty of room directly above the sender. The trickiest part is getting to and reinstalling the bolts on the sender..... NOTE : Make sure the gasket is on the sender before you insert it into the tank. (not something you want to forget). Then it's just a matter of screwing in the bolts and reattaching the wires.

Testing: You can test the sender BEFORE installation by putting an OHM meter on the two leads and check the resistance as you move the float up and down the shaft.


Starboard:

Location : In the aft cabin there is a little alcove on the starboard wall that has a mirror. There is a large access panel on the shelf below the mirror. It is secured by Phillips head screws. Remove the little plastic covers over the screw heads and unscrew the panel. The fuel sender is aft of the opening about 5" secured by 5 allen wrench bolts.

Replacement: I replaced with Royce Industries Flexi-sensor P/N:1-0520-1134-0250 Desc:Flexi-Sensor, flange mounting, 30-240 ohms output, 25-inch length.

Installation: You will not need to remove any additional panels. You will notice a great deal of space above the sender behind the wall. What you need to do is carefully slide the sender, top first, aft upwards and back angled a bit to the starboard corner. What you want to do is get it far enough and high enough that you can fit the end of the sender into the tank. It just barely fits into the opening. Once you get it in the opening you carefully continue to feed it into the tank..... NOTE : Make sure the gasket is on the sender before you insert it into the tank. (not something you want to forget). Then it's just a matter of screwing in the bolts and reattaching the wires.

Testing: You can test the sender BEFORE installation by putting an OHM meter on the two leads and check the resistance as you move the float up and down the shaft.






------ Initial First Post below for reference --------

I checked out the fuel gauges today and I think they need to be replaced.

I also checked the resistance of the senders behind the dash gauge and they were all over the place with readings. I can't tell at this point if its the wiring or the sender.

It seems like the port sender is under the ice maker. So the ice maker has to be removed?

The starboard sender seems to be accessed in some contortionist way from the panel behind the helm chair. Am I right?

Seems some of the simplest jobs get complicated due to fit.

 

[HUMPH]

If yours is like mine they are as follows:

Port side is either under the ice maker or in the storage compartment forward of the ice maker. There will be a fairly small access hole there to access it. Mine was in the storage compartment and they carpeted over the access.

Starboard side is accessed through the mid berth outboard cabinet. Open the cabinet doors, remove all of the crap in there and there is an access hatch to get to the sender.

Good Luck!

 

[Boat Guy]

I'll take a look, thanks.

 

[ttmott]

I believe all you have to do on the starboard side is remove the access hatch on the bottom of that little cubby above the seat (where the two lights and mirror are) and you will find the gauge right in there. Six screws....

 

[Boat Guy]

Yep, starboard much easier to get to.

I think the port is under the ice machine.

 

[HUMPH]

I believe all you have to do on the starboard side is remove the access hatch on the bottom of that little cubby above the seat (where the two lights and mirror are) and you will find the gauge right in there. Six screws....

Isn't that what I said?

 

[ttmott]

Sorry- when you said "open the doors" it threw me; no doors there.

 

[HUMPH]

Sorry- when you said "open the doors" it threw me; no doors there.

Yours is an open cubby? I get it, mine has mirrored doors.

 

[ttmott]

Yours is an open cubby? I get it, mine has mirrored doors.

Yup - the 400DA's are open. I wish it had doors then I could fill it up with more stuff.

 

[Boat Guy]

Haha...too funny... got it guys. Now I need to get to the port side.

 

[Boat Guy]

Ok, So I bought senders from Royce Flexi- senders and I can't fit it through the opening on the starboard side.

I opened the panel above the tank in the aft cabin, but the angle is to much to fit the sender in. Are there baffles in the tank? It's hitting something.

Do I have to take of the aft side of this cubbyhole? If so, how do you do that? There are a couple of outboard screws, but when I unscrewed them it didn't budge.

 

[Boat Guy]

And another thing.....WHY didn't Sea Ray just put the sender under the huge opening above the tank??????? The opening is like, what, 26" x 9" and they couldn't get the sender under it? It had to be about 5" off to the aft? ARRRRRRGGGGG!

 

[Boat Guy]

I've got to bump this thread.....

I'm sitting here with the old sender bent getting it out and no easy way to get the Royce sender in.

 

[fwebster]

Yes, the tanks do have baffles in them.

Send the Royce sender back and call Florida Marine Tanks and buy the correct replacement from them. They built the fuel tanks and supply the senders to Sea Ray.

 

[Boat Guy]

Frank, I recall a few guys saying they put these in. So it should be doable.

 

[Boat Guy]

Updated the first post with installation instructions of the Royce Flexi-sensor sender on the starboard side.

BTW- It works great. I thought I was close to out of fuel. Turns out I'm carrying almost a full tank.

Port side next - If I can figure out how to get the ice maker out.

 

[peterkvs]

On my 99 400 DA the access panel on the port side is under the carpet in the cubby next to the ice maker. You need to remove the support wall on the right side of the ice maker as the carpet is under it, and the wall o. The right end of the cubby. Then you can pull the carpet up and get to the access panel. If it turns out you need to move the ice maker you can just slide it side to side to get access. You might have to remove the ice maker water supply hose. I have never figured out how to get the ice maker out without cutting something.

 

[Boat Guy]

Thanks Peter, you're correct.... It was under the ice maker (of course)...

I'm looking at this ice maker wondering the best way to get it out...

 

[peterkvs]

Looks like the only options to getting the ice maker out is to either remove the panel that holds to doors in place, which looks next to impossible, or cut the face panel that goes around the icemaker in to left and right halves so that it can be removed from the icemaker. Once that panel is removed I think you can get the icemaker out. I am surprised that no one else has had to do this and posted it here. I looked a while back and never found any info. My icemaker gets cold, but does not make ice. I use it to store a spare bag of ice which works great and so I haven't decided to remove it yet.

Pete

 

[Boat Guy]

Yep mine will get cold too, but doesn't make ice....I honestly haven't looked that closely to see if it's fixable. But, seeing that it's as old as it is, I'm sure it's on borrowed time....

I'm looking at options...

I'm just happy I got the senders in. The starboard one was a real trick....