the clip keeps the o-ring compressed 'just the right amount'.

as with all o-ring sealing situations ..that's fine at first, and for a
while...
but after a while the o-ring gets mushy or soft ...and it's no longer
enough compression  of the o-ring to seal therevery well.

On 8/24/2013 1:51 PM, David Beierl wrote:
> 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
>