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Just from reading this two or three times, I would think it is a problem with the windings on the tank sender.
There is a flat strip with fine wire wrapped around it. Then the contact point on the swinging arm rubs on a particular part of those windings. It is possible that at some different gas levels, that they are not making a good contact. You could test that theory by keeping an ohmmeter hooked up to the sender while slowly filling the tank. (disconnect the wire, and test the sender only). Or, take the sender out and manually work it slowly to see if the ohmmeter shows some bad spots. |
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Gas gauge problem
take the wire off at gas tank , jumper wire it to good ground , if it moves the Gage , its your sender .
but check to see if tank is grounded first ,it lies in rubber strips and bolted in , rust or corrosion . ohm meter it to check for ground . you could also jump tank to good ground first , to see if gage rises to your known fuel level . |
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