My '95 has always clicked off repeatedly while filling fast with the nozzle inserted all the way. My solution is to fill slowly and not stick the nozzle in as far. Regardless, the gauge doesn't register all the way full.
I once filled the tank (to full) by hand with my lawnmower gas can. I could hear the tank venting through the fill pipe as I filled it. Eventually, it was filled completely (by hand) and I noted that it was the first time that I ever saw the fuel gauge register all the way to the top.
My conclusion from this exercise was that the fuel tank vents "slower" than most cars. My S40 reacted the same way.
As for the fuel odor, I didn't experience that even when filled to the top.
I would say monitor the issue for a few fill-ups and keep an eye below the car looking for wet spots.
Maybe that was just an anomaly.
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