Dear MrNabisco,


Hope you're well. I've done this on '95 945. I'd like to amplify some of Steve's sage comments.

(1) Repeatedly soak hose clamps with PB Blaster (or other penetrating oil) to ease removal.

(2) besure to remove completely from the work area, the heavy-duty rubber hose, that connecting the steel fuel filler pipe to the top of the send unit. You will not be able to re-install the send unit, with that rubber pipe in place. There is not enough room to "push it aside". It must be completely removed.

(3) The 90° fuel hose connector has an outer "collar" that moves. You have pull "up" on the collar, while pushing the entire connector "down" (towards the top of the send unit. These "contradictory" movements usually release the connector from the send unit's steel nipple. Grip the collar between your index finger and middle finger, using the center part of each finger (on either side of the collar). Then, put your thumb on top of the plastic arm, to which the fuel hose connects. As you gently squeeze the collar and pull it upwards, use your thumb to push down on the connector's arm, the connector should come free. If it doesn't, try to get some PB Blaster into the center part of the connector, where it will weaken any corrosion, that keeps the connector from releasing.

(4) When reinstalling the send unti, keep in mind that the bottom of the barrel must point straight towards the fuel tank's floor, i.e., towards the ground. There - "path" - the space inside the tank through which the send unit's barrel must be moved, is narrow. It may take a few tries before the send unit seats properly.

Hope this helps.

Yours faithfully,

Spook