The volvo dealer would have only told him he could buy a new one from volvo.

First, I told him there are sources online where he can get a new sender for $75-$100 less.

Second, I told him he could go to a junkyard where he stands a much better chance of finding a decent sender and getting it cheap.

If you want to epoxy electrical wires together on your car near your gas tank please, by all means, knock yourself out. However, that is not a real "fix" of the problem, and I said as much in my previous post. You are also assuming it is the connector and not the sender arm that is faulty. If it is the latter then your fix is useless since it won't solve his problem.

I recommend he replace the unit outright. He can drive without power to the sender and pre-pump without any adverse effects, so taking his time and finding a used one is perfectly fine. The stalling on corners problem some people note is a crock; it has to do with a faulty hose to the pe-pump and not a lack of power to the pre-pump. However, the lack of a pre-pump will strain the main pumpand shorten it's life, so it's best to replace the unit as quickly as possible.

As I said man, to each his own. You like to glue your car together that's your business.

-rt