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Art has it right--if it's leaking past the threads, it HAS to be pretty loose in there.
I see what's happening. The sender ripped off at the top part while the bottom kept threading happily down. Since it's well lubed (is this a good thing?) it HAS to be pretty easy to get out...
But there is SUCH little room back there...
I wonder...
Could you drill through the firewall from the inside? I'm trying to figure out where it sits in relation to the heater box. If it's above the heater box, you could probably drill through the firewall to get that stupid thing out, then put a grommet/plug in it's place. I mean, it would be a hell of a lot easier than yanking out the head or the engine. And risking breaking more stuff in the process.
If you can make a little dimple for reference in the firewall, and can see that dimple from outside (or inside depending on which side you make the mark) then you can figure out if that could work. You could do most of that from either under the hood or through that center "speaker" grill at the top of the dash.
But that involves making a hole in the firewall. Which is a little bit of a negative. The positive is it avoids tearing apart your new engine.
Dash in/dash out, 1 hour or so, total. That should give you all the room you need. If the thing is accessible from that direction, that is.
--
Chris Herbst, in Wisconsin.
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