"I was literally 1/4" away from having it back in, but the sender could not be budged in the ring."

That sounds like you put the seal (ring?) on the tank and are now trying to insert the sender. I'd try putting the seal on the (lubed) sender first, then lube the outside of the seal with dish detergent and see if the seal-sender combo will go home.

I honestly don't recall which way I did mine—nor does Art's pictorial mention it, but at this point I think this approach is worth a shot.

Thanks for the part # and price info.For future refrence, OE parts are discounted a good 20% at the Tasca Auto Group in Seekonk, MA, with low-rate (commercial) UPS rates. See http://www.getvolvoparts.com/, where I just got the following:


Multi-Part Search

Part Number Search Results : OEM Catalog
Item Number MSRP Core Price Price
94454444 $205.19 $0.00 $151.02

FUEL PUMP
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Bruce Young
'93 940-NA (current), 240s (one V8), 140s, 122s, since '63.