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Shaner,
I recently changed out the fuel gauge sending unit on a 95 960 so the process is still clear in my muddled mind.
There are good instuctions on the 900 FAQ. I suggest reading them. Several folks here on the list have performed this R&R so there is a great knowledge base here.
I suggest having the tank be at 1/4 fill or less.
The access hole is under the carpet in the truck. (Under the rear deck on the driver's side.)
Do this outside with good vetillation and I highly recommend a VOC mask and safety glasses.
After lossening the 5" SS screw clamp around the locking ring, the only way I was able to remove the locking ring was with a long crow bar placed against the tabs on the locking ring at about 3:30 - 4 o'clock and using the right rear corner of the access hole as the fulcrum. The tank is plastic (as is everything else you are working on) so don't go Hercules on anything.
I also needed a small crowbar to gently pry the unit our of the tank. The gasket fit was very tight. Once out, you have between 4-8 hours to reinstall the gasket otherwise it will swell beyond use and you will have to get a new one. Not expensive but a potential pain.
I put the gasket right back in immediately after I got the old unit out to minimize swelling. I coated it in vaseline to make reinstallation much easier.
Have patience taking the unit out. You will have to rotate the unit (clockwise I believe) from the 12 noon position to the 4 pm position after pulling the unit out of the tank ~1 inch. There is a baffle in the tank you need to get around. Reinstallation will be the reverse.
Double check for leaks when you are done and have filled up the tank. There are 4 hoses attached to the in tank unit so make sure there are no cracks or tears in any of the hoses after they have gotten wet.
Did I mention have patience....... ;-)
DEWPO
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1998 S90 070,050 and 1995 964 153,010
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