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Discussion Starter #1
Heres the deal:

With old gas tank, gauge worked fine.
With new gas tank, gauge reads between 1/4 and 1/2 with tank full.

Did the diagnostics - disconnected tan wire in trunk and gage goes past full. Ground the tan wire at the harness in trunk and gauge goes to empy. All good, right?

This is the part that has me baffled - when I disconnect the sending unit ground wire I get no change at all. When I jumper that ground to a known good ground I also get no change. Same thing with a new sending unit.

I tested both sending units with jumper wires in the trunk, and both operated the gauge as they should - float up is full and float down is empty.

Any thoughts? The only thing that comes to mind is that perhaps the tan wire that clips to the sending unit is bad at some point between the connector on the sender and the connector in the trunk, as this is the only section of wiring that hasn't been "tested". I do remember when I originally removed the tank I forgot to disconnect that wire in the trunk and had a lot of tension on it before I figured it out. Anyway - thanks for any ideas.
 

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Al, I think you hit the nail on the head with your last paragraph. Did you tape the wire into the trough before you put the tank back up? You could have crushed it between the tank and trunk floor, and you're getting a "high-resistance" short to ground before the sending unit.
 
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