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OK--here's the scoop with my "cheapo" voltometer---with sender disconnected, moving the arm from up to down get about 14-55ohms. With blue wire connected and battery ground on sending unit gage goes form empty to 1/2 full with float travel from up to down. I get about the same results with the other sending unit in both cases. Whaddya think?

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Your checking everything proper and to back up a second the gas gauge reads E w the blue wire disconnected & when you ground it, it swings over past F. I thought maybe the sending unit was bad but this is the 2nd one & same deal but my gut tells me it's something w the sending unit. I am out of ideas

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And you're probably correct Robert...I'm betting the aftermarket unit just is'nt close to the correct sweep judging by the values that have been stated...Bending the stop won't give that much more on the top end...And since taking out the cluster for caliberation/sender sync is not on the list there's only one quick fix...You need to bend the float arm before it contacts the upper stop...The basic idea would be to bend the arm in a way that would rotate the center stud up further to gain the values you need for a full tank but keep the float in the same general orientation....Now, you may not get it to read completely full without the actual rallye gauge caliberation with the sending unit...but you'll surely get a much more accurate, useable needle sweep and reading...

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Bend the arm before the stop. Get your reading down around 10 ohms, then you got it.

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This is bugging the hell outta me

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Me too and I went out & measured mine(65 dart w 3/8 unit) & I just filled the tank yesterday & I got .1 ohms!

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I could bend the arm to accomodate but I wonder about the lower end readings??

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--any other thoughts anybody has I'd appreciate knowing

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Yes it's a very good idea to not peg it, to have a helper & unhook it as it swings rapidly toward(& crosses the F) but with my sending unit having .1 ohms at full tank it's damn near pegged electrically. Take a 5 gal plastic bucket filled w water set next to your tank & run 2 jumper wires to this sending unit & dunk it & w a helper see what the gas gauge reads with the float being raised by the water under operating conditions rather than by hand(I was thinking you might be bearing slightly sideways on the float arm & lessing its contact, kind of grasping for straws now but getting desperate for ideas ). This would give you a good visual for bending it. I still think the resistance wire is the wrong ohms.

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I'm jumping in here late, but sounds like a sender problem. Bending is only going to get you that last little bit. I wouldn't think you're going to make up 1/2 tank.

Good luck

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