Sender and Fuel Pump Replacement
With the tank out and on the ground, now is a good time to take a (non-metal) brush and clean all the dirt and debris off the top of the tank, especially around the sender assembly, so it doesn’t fall in when you remove the sender.
The sender is held in by a locking ring, which (technically) has 6 tabs sticking up. 3 of the tabs are stop tabs that stop the ring from spinning further when its fully locked in place, and the other 3 are flat tabs. Do not use the larger stop tabs to remove the ring; use the 3 flatter ones, and I recommend a brass or non-metal chisel-like tool to avoid creating any kind of spark. Use a small hammer to tap against the flat tabs to spin the ring counter clockwise until it unlocks. Once the ring is unlocked, you can remove both the ring, as well as lift the entire sender assembly and o-ring out of the tank. Again, be careful as now you’re opening a container that still has gas vapors in it.
With the sender removed, inspect the inside of the tank for dirt and debris, and clean as necessary. The factory tank has a plastic baffle under the opening, so you can lean it to one side to pool the gas on one end while you wipe the baffle clean with a rag. Do not stick any flashlights into the tank! Next, using a rag to stop dirt from falling in, clean the groove around the opening that the o-ring sits in, as any dirty or corrosion will cause the new o-ring not to seal properly.
Installation of the new sender is essentially the reverse procedure; the new o-ring should be lubricated with the included silicone lube so it seats nicely into the groove, and should be installed with the tabs pointing into the tank. Place the o-ring in place, remove any bags or packing material from the new sender and sock, and lower it into the tank. Clock the sender so the fittings point towards the indentation for them on the top of the tank, and if need be, you may have to bend/flex the fittings a little to get the sender to sit perfectly flat in the hole. Once you do, you can place the new locking ring in place, and tap it in a clockwise motion until the stop-tabs prevent it from going further.
