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PostPosted: Thu Oct 28, 2021 10:53 am 
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Joined: Mon Aug 13, 2012 11:04 am
Posts: 13
Location: Geneseo, Illinois
Year and Trim: 2000 SSEi 108,000 mi.
Hi all!

I recently added a 2000 Bonneville SSEi to the fleet, and it has a flaky fuel level sensor that I'm trying to replace. Managed to get the lock ring & everything loose, but the cup at the very bottom of the fuel pump seems to be a slightly larger diameter than the tank opening. No matter how I try to orient the pump, I can't get it to fit through the opening.

Am I missing something here?


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PostPosted: Thu Oct 28, 2021 3:30 pm 
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Certified Bonneville Nut
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Joined: Mon May 10, 2010 6:11 pm
Posts: 9331
Location: Chicago, IL
Year and Trim: 2003 SLE
I had this exact issue twice since I had to replace my fuel level sensor twice lol...

I use a small screw driver to pry against the fuel pump cup and force it out of the hole. It wasn't a dignified experience and it had me sweating into the fuel tank but I managed to get it out.

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-Car Guy Carl
"Penelope" - 2003 SLE - 228k Miles
"Sydney" - 2000 Honda S2000 - 89k miles
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PostPosted: Sun Oct 31, 2021 12:28 pm 
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Joined: Mon Aug 13, 2012 11:04 am
Posts: 13
Location: Geneseo, Illinois
Year and Trim: 2000 SSEi 108,000 mi.
Thanks Carl. Now to wait until it warms up a bit so I can work on it again. Hopefully I can get it fixed before the snow starts flying.


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PostPosted: Tue Nov 02, 2021 9:06 am 
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Joined: Mon May 19, 2008 6:04 pm
Posts: 25579
Location: Browerville, MN
Year and Trim: 2004 GXP - plus a handful of other Bonnevilles
I've removed dozens (maybe hundreds) of these dang fuel pumps, every single one is larger than the opening in the tank. You really have to force it. I usually find the spot it opens the most and then twist from there (kind of how you take a tire off a wheel). Even with the force, I've never broke one. Your results may vary. :P

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-Andrew-
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2004 Bonneville GXP | White Gold Tricoat | custom built supercharged 3800 hot rod | garage queen
2014 Town & Country Limited | Cashmere Pearl | 52k | Family Hauler
2002 Ram 1500 Quad Cab Sport | Black| 230k | Official Bonneville Hauler


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