Replacing fuel tank sending unit

[68barracudaconv]

i have never changed a fuel sending unit and have the following questions for all you pros at forabodiesonly.
1 Are there any unusual tool required?
2 What are the possible pitfalls associated with a rusty old unit being removed?
3 How is the new unit sealed to prevent leakage, gasket, o-rings, etc?
4 How do you clean the rust away from the opening if necessary without causing a spark?
5 Can you ground the unit to the frame as well as the gas line?

Thanks

 

[RedFish]

The new sender should come with a new seal ( flat neoprene ring ).
Chassis ground is needed but a simple jumper over the fuel hose accomplishs this.
There is a special tool for the lock ring at the sender but I've never needed it. Small hammer and a brass drift works for me.
I haven't had rust issues at the sealing surface.