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.

You just might be overfilling it. The older canister style fuel sender units tend to get dirty on top and do not register as 'full'. This has happened on two of my 850's with an easy fix: Remove the sender, let it dry out a bit, repeatedly turn the sender up side down causing the internal plastic bit to slide all the way up and down the shaft, then plug it in and watch the fuel gauge go from empty to full. Reinstall the sender.

The smell of gasoline is a bit troubling as there should never be any of that. It could be a cracked filler hose or air hose at the top of the tank. The only way to find out is to jack up the right rear and inspect with a dry paper towel.
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Keeping it running is better than buying new