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Is it possible to remove and install a gas tank sending unit without removing the quarter window? I'm having no luck getting the window out. I can remove the screws holding the unit but am leary about getting the old one out and especially getting the new one in without damaging it. Has anyone done this successfully?
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NO. The sending unit float-arm is 22" long and CANNOT be teased out of the tank without considerable damage,due to the lowness of the roof, side-windows & decklid. Your only other option is to remove the engine & transaxle, then the gas tank. This in fact was the only way until someone recently came up with the quarter-window removal that gives plenty of access for this job.
Depending on your car, there may be paint sticking things down, or the edge of the gill may be touching the window frame. Try removing the wing-nuts that retain the gill, then pull the gill off. Careful prying between frame & body WILL move the window and its stiff, 32-yr-old rubber gasket. I have yet to see a frame pop-rivited in, but someone may have modified your car. Check in the door opening area, then drill 'em out if necessary.
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