I have read the posts about replacing the fuel level sensor and all is well except I cant get the damn thing out of the tank!!! It seems the unit is just a hair bigger than the opening!!! What gives!!! Anyone have any ideas????

You have to angle it slightly to remove it, kind of a puzzle.
This link might help.
http://www.bonnevilleclub.com/forum/...=asc&start=120

so, will I have 'bend some tabs'???? Should just come right out, correct?? I have tried EVERY angle to get it out!! There is a good 1/8 inch size difference!! What am I doing wrong!!! Do I have to remove the black plastic ring? That is what is holding it in there. The new assembly came with a black rubber 'thing', like a really big/thick gasket that looks like it goes in place of that. I tried prying the one out of there but it is rigid plastic???

I had the same problem. It seems that the plastic absorbs the volatiles in the gasoline and expands it a bit. I solved it but it is hard to describe in writing.

I tilted it and twisted. There is flat area that you can use to get the thing out of the hole a bit and the rotate while it is tilted. This will give you some leverage and help you use the circumference of the hole to squeeze the plastic piece slightly. The action of rotating will allow you to sneak the whole perimeter of the plastic above the lip of the hole.

I doubt this makes sense on its own. But if you read it a couple times and then go wrestle with the sending unit, I think it will start to get clearer. . .

Hawkjet, I edited my post at about the same time you replied. Can you tell me if I can take that black plastic off???

The black rubber thing is for the different car. The rigid black plastic on the perimeter of the tank hole was pretty well attached and since I found a way to wrestle things out, I didn't try any more.

Dang!! So I probably shouldnt try and take it off of there?!