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I changed my fuel filter and replaced the o-ring with a viton 247 like I read a lot of other subscribers do. I had to pull it back apart due to a leak at the fuel level sensor. The o-ring swelled up a good bit and doesn't fit anymore, is this normal, or do I have a bad batch of o-rings? It was only exposed to gasoline for about 24 hours.
 

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Hard to tell the difference between a Buna-N (which it sounds like you may have) and a Viton unless the Viton is brown. Buna-N would be more likely to swell. The Viton should hold up better then what you describe. May have received the wrong O-rings?

http://www.marcorubber.com/material_chart.htm

If your Fuel sensor leak is coming from the plastic nut being cracked I have a replacement if interested. See link below

Good Luck with it.
 
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