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is there any way to drain the gas in the tank before dropping it?
does it all need to be drained - or can it be dropped with a few gallons left in it?
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If you have the equipment and or the extra hands it's much easier to pull the bed off and set it behind the tank. Did this with my 00 Z71.
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what about the difficult to connect/disconnect stuff? I seem to recal the evap lines suck to disconnect.
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Not sure bout the evap line.
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the sending unit retaining ring - can it just be tapped off with a hammer and punch or do I need the tool for it? (and is there a spark/gas fume hazard?)
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A hammer and a flat blade screwdriver is how I got mine off. Shouldn't have to worry bout a spark or fume hazard if your out in the open. Plus the ring spins off easy enough to not have to muscle up on it.
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last but not least - is there ANY adjustment necessary to the pump/sender unit (i.e. to make sure the gauge reads levels correctly, etc - or is it simply a drop-in with no adjustment needed? I think it is the latter, but wondered about that.
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Should be just a drop in and no adjustment kind of thing. Didn't do any adjusting when I did mine and the gauge reads just fine.