Tool for removing fuel tank bung plug

You should buy a new locking ring and take it to a metal fabricator for them to make the tool to fit it.

it only needs to be a T bar with two rectangles 180° apart to mate with the cutouts in the ring.

Where abouts are you from?

74wagon I'll take a photo of my tank sender tool when I get home. I bought it from someone on here ages ago.

You'll want to get a new 'O' ring for the sender, too.

I've always just done this using a long flathead screwdriver and a rubber mallet, and worked my way around the sender ring a few times until it's open, takes a couple minutes but not especially difficult.

jamesinc Seconded. Rubber grease on the old o-ring also.

volvodriverman oh yeah it makes a huge difference, I didn't think to mention that. I use Herschell Red Rubber Grease. SCA have a home-brand version that I'm sure is fine too.

FCP Euro and ipd USA both sell a tool to remove the ring. Might be worth buying one as they're not too expensive. Shipping shouldn't be too expensive given you're in North America.

https://www.fcpeuro.com/products/volvo-fuel-pre-pump-sender-tool-skandix-1015486

https://www.ipdusa.com/products/5427/Fuel-Tank-Bung-Nut-Tool-for-Volvo-IPD-106653?srsltid=AfmBOopQXjcBRDhJ-1IxVhZiDbbwBaqc7JS_uebKw1mwVnpTtsv3eP7m

Okay, so ... looks like I've got a Skandix one.

Measure the ID and OD of your tank lock ring

1974Wagon Hello Major Ledfoot. Can you confirm that the Skandix tool fits the 140 (all of the compatible cars listed on the FCP site are 1978 240's and up)

I'll do that on Sunday when I get back home (& if it's stopped raining). 78+ tanks are different since the tanks for injected cars had a lift pump attached to the fuel level sender, but I can't recall if the lock ring is similar to the earlier ones prone to internal pipe corrosion and vapor lock.

Major Ledfoot The lock rings are similar but they are different diameters, the no-pump tank has a smaller opening.

74wagon Good luck with the rain

Thanks! And I did (with the lack thereof).

So, I tried fitting the Scandix-type tool on my 145's tank.....
(note bodgy K-Jet external fuel pump fitted, just so I could move the car)

.... and it fits on the 145's old fuel tank sender, without dramas.

That's fantastic. Thank you very much for doing that. I will go ahead and get myself one of those

Just became aware of this thread today and thought I'd throw my two-bobs worth in, I'm replacing the external and the in-tank pump on my 84' Estate and thought I'd jury-rig a tool to do the job despite being aware of the "alternative" arrangements circulating online. A quick once over with the vernier calipers and a trip to Bunnings yielded this little number

Crude but efficient, got rid of my welder years ago but still have the oxy which enabled me to form the bent tabs, I'll just throw a big adjustable spanner on the end of the bracket overhang to get leverage when turning….