I know this kind of thread has been talked about time and time again, but here it goes..... When the car is full of fuel, it reads just above 1/4 tank. New sending unit, and yes when its grounded the gauge does move. Installed a new circuit board, replaced the voltage regulator for the fuel gauge, even installed a different cluster all together. The weird thing is, when I barely put the connector into the back of the cluster, (the end that has the yellow with white stripe coming from the fuel sending unit) the fuel gauge works! But once its fully seated into the back of the cluster it goes back down to empty. I cant find any broken wires, exposed wires that happen to be touching each other either. Besides running a whole new wire from the sending unit to the back of the pigtail going into the cluster, is there anything else i should be looking for? Any help would be greatly appreciated. I'm usually pretty good at figuring this stuff out, but it has me literally wanting to rip it all out and going a different route that will cost a me a fortune. Again, any help would be appreciated!
Pull plug from tank. Jump the wires across the plug to each other. With key on, gauge should now go to FULL. Check that.
In spite of what Frank may tell you (his std answer)it isn't haunted. Apparently something from other portion of harness is causing the issue. Fuel gauge is contact #5. What I'd do is gradually insert plug on angle to see what contact(s) kill the gauge. There could be a point it stops working. At worst you can remove contacts a couple at time to see when gauge fails. A piece of thin tape over other PCB contacts will rule out problem in the plug connections. At that point, you'll know if plug can work when fully inserted. This sounds like a incorrect splice or short in harness, possibly from damage or a past miswire.
