2005 260 - how to access fuel sending unit

R

robertpel9

New Member
Jul 4, 2021
26
Boat Info
2005 Sea Ray 260 Sundancer
Engines
Mercruiser 350 Mag with Bravo III
I am having an issue where i can smell fuel and occasionally see some minor amount in the bilge only immediately after filling the take to the top. boat is wet slipped in Newport Harbour and i really dont want to pull it out but i know any fuel issues are a real safety issue.

I have a feeling it is the sending unit that is leaking as this only happens when the tank is just filled and then it goes away after a couple of gallons are used

I cannot figure out how to access the unit. I went into the bilge and followed the fuel lines through the filter and all the way to the fuel rails and everything is dry and tight

How can i access the sending unit to tighten the bolts or maybe replace the gasket if i see this is the issue. This is a 2005 260 Sundancer

Many thanks
 
First, this probably goes without saying, but DO NOT use the boat until this is fixed and the gas/fumes are fully evacuated. Don't even touch the battery switch or anything. Ideally, open the hatch by manually pulling the release pin. It takes only a very small amount of gas to create enough fumes to cause a problem... one that you likely won't get a second chance at.

If you can't see the fuel sender from the bilge, it's most likely accessed through the mid-cabin. There may/may not be an access plate - in this case, remove the center section of the mid-cabin berth floor.

Use a regular screwdriver - not a power driver.
 
I own a manufacturing factory and my head mechanic is very versatile. I'm going to take him down there friday as opening the hatch manually is not a one person job and i dont know what i am going to see when i open it, a tiny bit of gas or a gallon......

Then i guess it is just tracing everything out and finding out what is not tight or is leaking, replacing those parts and getting back going

I would hope it has nothing to do with the tank but from what i am told the ploy tanks should be fine and this is likely the sending unit gasket or perhaps the fill or vent hose

I actually was going to turn the battery on and run the blower before opening the cover but you definitely have me rethinking that idea
 
Yeah, this is one of those times when it's good to take the safest course of action possible. Eliminating any "possible" sources of spark. The 260DA hatch isn't "that" bag - you can certainly do it by yourself, but it's definitely easier with two. Bring a 1x or 2x and a saw to prop the hatch open.

While there are multiple places for leaks, the fuel sender gasket is the most likely.

Bring plenty of rags and immediately take them out of the boat - a metal pail on the dock would be a good idea to toss them into. You can burn them later.
 
Maybe i can help. Your boat is a newer version of mine so its not like a bunch of places to put it. In the bilge behind the aft cabin wall, in front of engine you may see a plywood wall, on that wall may be a circuit panel and fire system. Behind that wall is the fuel tank with the water tank on top. Small gap between the two, just enough to see the sender access cap, but pretty much have to pull water tank to fix it.
#2. Aft cabin, remove cushions, remove center plywood base for bed. Tank under there.
Pray this is it cause first location is a pain in the ass. I have the first my sending unit is off. I use a calculator to track fuel mileage and distance.
 
My opinion based on knowledge of this model. I doubt you sender access cap is the problem. Think about it, it’s on the flat top of tank. Unless you are way overfilling the tank, how would fuel get from there to bilge? My guess. An issue at where the fuel hose goes into tank. Loose fill hose fitting or crack in the neck the hose connects to.
Or where the vent hose exits the tank. Those vent hoses are cheap thin corrugated and can crack over time.
 
Pirate Lady said:
My opinion based on knowledge of this model. I doubt you sender access cap is the problem. Think about it, it’s on the flat top of tank. Unless you are way overfilling the tank, how would fuel get from there to bilge? My guess. An issue at where the fuel hose goes into tank. Loose fill hose fitting or crack in the neck the hose connects to.
Or where the vent hose exits the tank. Those vent hoses are cheap thin corrugated and can crack over time.
Click to expand...

Are these hoese easy to ID and replace. Last night it was dark when this happened i lened into the bilge and could see two hoses coming out of the tanka nd going to a fuel filter and then to the engine. all of that was claena nd dry. I could see the tank was esstially completely full (less than one inch from the top but the access to the top of the tak was VERY small
 
Rob my man. You were looking at the wrong tank, it’s possible under the right conditions you can see the level in the fresh water tank, its opaque plastic.
The fuel tank is aluminum so unless you are Superman there is no way you are seeing the level of liquid in the tank.
 
Pirate Lady said:
Rob my man. You were looking at the wrong tank, it’s possible under the right conditions you can see the level in the fresh water tank, its opaque plastic.
The fuel tank is aluminum so unless you are Superman there is no way you are seeing the level of liquid in the tank.
Click to expand...

Are you sure on an 05-09 260

I see two other tanks, my waste tank and what i assumed to be the freshwater tank asthey are much smaller. The tank i am looking at is huge and right in front of the engine with lines coming out of it that go through a filter

I may have gotten lucky as there was a cancellation from the main repair place here in Newport harbor and they do mobile repairs. they are definitely not the cheapest option but they are free thursday and with a fuel system and liquid gas in the bilge this is probably one of those times it is best to just pay up.....
 
Pirate Lady said:
The fuel tank is aluminum so unless you are Superman there is no way you are seeing the level of liquid in the tank.
Click to expand...
The fuel tank is plastic. A lot of things have changed in three decades ;)
 
It was the sending unit gasket. Had it replaced by a marine mechanic and all is well

many thanks!!!!
 
Well I’ll be dam. What i say above, no way its that? Ya, listen to my advice next time. Glad it resolved.
As Colonel Nathan Jessup said in A Few Good Men “Dont i feel like an ass”.
 
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