At 01:20 PM 8/24/2013, David M wrote:
>Ok, I finally got the clips out (TWO identical ones). No-one ever
>mentioned two clips! Used a 2" long screwdriver. I would imagine
>reinstalling the clips will be a pain because I have no idea where
>the second one goes.

Sounds as though the person installing the sender didn't have an
O-ring the right thickness, or else that the thermostat housing is damaged.

Time to get eyeballs on the thermostat housing maybe?  I'd get some
PB-Blaster onto the bolts in case it needs removing, they've been
known to break on removal.  And a new thermostat housing wouldn't be
amiss at this age regardless, it's 25 years old now.

As I recall the proper O-ring is quite fat.  I *think* it should be
doing its sealing against the wall of the cavity rather than by
pressure from the clip against the bottom.

Yours,
David