Yes, I did note as well that there are a few differences here and there between the years. I think that pulling back the interior of the trunk was needed for everyone (but never mentioned). Looking forward to seeing how it went
You know, I'm really glad you made that post, because I had completely spaced my reply.
OK, so... here's how things went:
As I mentioned in my first post, I had taken everything apart the day before... all I had to do was assembly. Well, not really.
When I got to actually trying to pull the filler tube out of the grommet I realized that there was only about a half-inch of rubber left intact around the filler tube. The rest of the grommet was already torn in half and what was left was acting a lot like a door stop. Every time I'd try to pull the filler tube out of the tank it would slide into the space between the tube and the tank and just jam things up. So I had to take a small screwdriver and deliberately push the inside half of the grommet off into the tank. {{insert sad face here}}
So my first step at reassembly time was actually to fish the back half of the grommet out of the tank. I'm 6'4". I have big hands. Getting it out with my fingers was not going to happen. So I picked up a small shop-mirror-on-a-stick and grabbed a coat hanger from the closet. Bent the coat hanger into a hook and used the mirror to (sort-of-kind-of-but-not-really) see the ring and fish it out. As luck would have it, I was working at the right time of day and the car was parked just so. The sun shone thru the hole where the filler housing had been, thru the body panels and into the gas tank. True story... it was the Harmonious Convergence all over again. All in all pulling that stupid chunk of rubber out of the tank took close to 90 minutes of curse-laden, sweet-talking, sweat-soaked agony.
But when I finally got it out... oh, the joy!
Anyway. From there, reassembly took about 30 minutes. I also went the lithium grease route, slipped the grommet into the tank, the filler tube slid right into the grommet, the tank bolted right back up into place (I did find that a 1/2" ratchet and a couple long extensions made this much easier than using the 3/8" equivalent), the housing slipped right into place at the top of the tube, the screws all went right back in the same holes. Everything was a dreamy dream.
The Entirely-Totally-Off-Topic Whine:
Then I went to return a 12v battery to Sears that hadn't fit in the car when I bought it. I had prearranged the fit test with the manager... and I'd had new keys made for the car earlier that day when I picked up the grommet at the dealership. Get to Sears, locked the car, did my business, got back to the car only to find out that the new keys weren't quite done right and don't work in the doors, just the ignition. Walk home, got a ride back to Sears from the wife. Fortunately Sears is only about a half mile from my house. Get back to the car with the right key, zoom zoom off I go... to the gas station. I start the tank filling and go to washing windows... had all the windows open, so I stuck the key in the ignition to roll them up. And, yes, forgot they were there. And subsequently locked the GOOD keys in the car.
Oh what a lovely day. It cost me $80 for a lockout... twice in one afternoon. Heck, twice in one freaking hour.
So I went for a NICE long joy ride after all that. At one point I punched it hard, I think I hit about 106 mph in a 60 mph zone... and about 90 seconds later a state trooper tails me into an off-ramp from one freeway to another. My heart stopped as my brain started calculating fines and trying to remember if 106 in a 60 was enough for an actual arrest or loss of license. Much to my relief, he never stopped, I moved over for him and he freaking FLEW past me. And I tried to keep the adrenaline from literally oozing out my pores.
BUT - the tank didn't leak and in the end that was all that mattered.
So, that's my story and I'm sticking to it. A few cliff notes don'ts:
- Let the back half of the grommet fall into the tank.
- Expect to do this without taking the trunk liner at least loose.
- Plan on doing this without the distinct possibility of having to at least loosen the tank straps if not remove one or both of them.
- Lock your keys in your car.
- Twice.
- Believe for a second that you'll ever get away with going over 100 mph in a 60 mph zone in front of a trooper again, in your entire life. Just... don't. And don't plan on buying any lottery tickets either. You used up all your luck on that one shot.
Anyway, all in all, it's not that big of a deal but it does take some mechanical skill, the right tools, some time, sweat and a bit of blood. Without this original post, though? I'd probably have taken it to the shop. So a big big thanks to davis03.
Oh, and, as promised, here are the pics of the trunk liner I had to take loose to get the top of the tube apart: