You could cut a hole, but I would only do it as the very last resort.
Your fuel gauge sender does not have exposed wiring on the sender side. Basically, wiring is all internal and terminates in a connector that is molded or fitted to plate of sending unit assembly.
What you need to do first is find the pigtail that matches your chassis. Auto parts store can be helpful here. I am 99% sure this is what the "rats" have chewed up and needs to be replaced anyways.
Second, look closely at the connector on the pigtail you just bought. Picture in your mind what exactly needs to be done to disconnect it. I found that a pair of 24" curved needle nosed pliers from Harbor Freight was just the trick that was needed on a 2003 Damon Challenger. Pretty sure it was an '03 Challenger, I can't put my hands on the work order from a few years ago but I remember using the tool. A flashlight and inspection mirror / camera will be a valuable aid, so will patience and a celebratory 6-pack of adult beverage.
Just checked, HF no longer offers the compound pliers that I used. Closest I could find were 16" single joint. A bit more difficult to use, but should still work if they are long enough.
https://www.harborfreight.com/16-in-...-pc-64082.html
Once connector is disengaged, should pull out with a bit of difficulty. Wire in the replacement and now your patience will really be tested. I discovered that a short piece of 1/2 pex or pvc pipe to be invaluable as a tool that can be used to push connector back into place. On both, cut a slit in it lengthwise on a table saw. Lay wires in through the slit and now you have a push stick. Extract wires through the same slit as you pull the push stick back out.
You may find that dropping the tank is unavoidable, but you don't have to drop it all the way. Rent a motorcycle lift or buy a hydraulic cart (harbor freight) to support the tank while you lower it a couple inches.
You may even consider dropping the fuel tank anyway. Or cut the hole. If your fuel pump has never been changed, then it is at least 19 years old.
If it were me, I would change everything anyways. But, I didn't just fill up my 100 gallon gas tank either.
This forum post might be helpful as well.
https://www.irv2.com/forums/f22/2003...mp-174149.html
Linear Mode
