I hoped to be able to report a successful conclusion to the fuel pump replacement, but it remains a work in process.

Da Dreaded Rubber Ring (from Kuba's post) would not allow the sender to seat. I was literally 1/4" away from having it back in, but the sender could not be budged in the ring. The WD 40 he recommended as a lubricant does not seem very slick in the 25 degree temps we've been having here in Chicago. The garage can be heated to about 50 with a sealed oil electric radiator, but I'm also opening the garage door half way to vent the fumes from the open tank.

Tonight I pulled the sender back out far enough to remove the ring and brought the seal inside to let it come back to room temperature.

I noticed on the old seal that there is a band of white residue around the ring close to the lip. I'm guessing that this is the remainder of white lithium grease that was used to install the pump before. I'm thinking about applying some lithium grease to the sender and seal. Basically the same way it was applied to the old seal.

Anyone have an opinion about getting a little lithium grease into the fuel?

It seemed to be the only lubricant that would allow the front oil seals to seat correctly with my jury rigged seal press tool.

Volvo part numbers and prices for the parts are as follows:

Fuel Pump 9445444-4 $208.00
Sealing Ring 1367623-4 $ 10.19

Car is a 1995 940 8 valve.

Roger