Re: How to repair fuel connectors
When I reassembled the contact and blue lock it took minimal pressure to engage the lock. Point; if you really had to force it, you need verify the pins conductor was not shoved out the back of the connector.
As in 1) visually look for the metallic contact. 2) insert a very small pin, needle, paper clip and verify continuity from the contact to the wire. What I am getting at is that by forcing the lock on, it may have crushed the contact or pushed it out. So even though the outer housing locks to the tanks sender, it may not be a good connection.
Another option is to pop the blue lock, extract both ground and sensor pins from connector and plug the wires onto the sensor. The contacts should firmly grip the male pins and not fall off. If they fall off, they are damaged and are likely the source of your problem.
An ohm meter to the tank sensor would be a good idea too. What does it read?