Working on a 1990 245. Owner had fuel-sender assembly and in-tank pump replaced w/ new earlier this year. Gas gauge didn’t work for long – started reading low/erratically; pump seemed noisy (yeah, it’s a wagon); thought he smelled fumes; car ran rough / cut-out at times.

I pulled the sender. Looks like aftermarket and poorly made – cover for wires on pump had broken loose; tabs that hold sender in place were loose. Clamps on hose between pump and tube were loose.

Float was cracked and partially filled with gasoline; large-o-ring under flange was swollen (or just too large from new) so that it was outside the groove and ring couldn’t be closed without bending the tabs up - which had been done.

Net: IME aftermarket parts aren’t all bad but this one is; and the install seems crude – perhaps someone not used to 240s.
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240 drivers / parts cars - JH, Ohio