The hole that is stamped into the tank had sharp edges on it.  You need to
dress those edges where the sender engages so that it will no longer bite
into the sender when you install it.  I also give the fingers around the
hole a very slight tweak so they are no longer flat, instead they have a
slight incline to them so they will not dig into the ramps when you go to
install the sender.  Finally I lubricate the o-ring with vaseline so that
the sender turns a little easier with no binding or galling.  If something
isn't working, doing it over and over again, isn't going to make it start
working.  Change what you are doing.

On Tue, Jun 22, 2021 at 4:49 PM Ralph Meyermann <ralphmeyermann@gmail.com>
wrote:

>  Howdy Volks a while ago I replaced fuel tank and sending unit, I
> encountered a grommet issue I thought it was atop the tank but had another
> to replace it. FF 2 yrs I'm Having fuel starvation issues, rubber grommet
> pieces. Ordered another tank, seal kit and sending unit o ring. Fuel leaks
> from sending unit  after replacing the seal twice. Sending unit does not
> seem to be snug enough to the tank to seal properly. Thinking  I need to
> replace the sending unit as well due to the locking notches are chewed/out
> of whack.  Thanks for your help
>

--
Thanks,
Ken Wilford
John 3:16
www.vanagain.com