Just wanted to make sure this is what the problem is before I go ahead and purchase a new one. With the tank full, the guage only reads about 3/4. It will never reach full. Does this sound like the fuel sending unit inside the tank. This is a problem that I have had for quite some time and it seems to be getting worse.

 

Check the voltage and resistance on the wires coming from the FSU before you buy another one. It could be the gauge.

 

What is the best way to check that, I know in the past I have taken off the clear linse to replace some of the bulbs. From there you can pull out the instement cluster if I remember right??? Not to good with electical, not sure what I would be looking for. But I am thinking its the sending unit. Those tend to go out as cars get up there in age.

 

This is simple and free to check. It is held in with a few screws and accessible with the inner fener cover removed from behind the drivers tire. Pull it out (but remember how it came out), have someone sit inside and move the float up and down, see if the gualge goes up all the way. All you have to do then is bend it down slightly and put it back in. Make sure the tanks isn't full thoug!

 

This is simple and free to check. It is held in with a few screws and accessible with the inner fener cover removed from behind the drivers tire. Pull it out (but remember how it came out), have someone sit inside and move the float up and down, see if the gualge goes up all the way. All you have to do then is bend it down slightly and put it back in. Make sure the tanks isn't full though!

 

The FSM shows how to test the sending unit with an ohm meter, simple test, hard part is getting the unit out. If the sending unit passes the ohm test, pull the cluster, remove the fuel gauge and look at the fine white wires wound around the bi-metalic strip. If there is any discoloration of the wires, the gauge is bad. Are you sure that you are getting the tank full? The gas pump nozzle will often shut off before the tank is completely full. Keep pumping gas until it will not take anymorre, then check the gauge.

I don't see any need to rebend the float arm, it shouldn't be bent in the first place unless it was removed and insstalled carelessly at a previous time.

 

Here's a bit of helpful info too:

http://www.frosted7.com/katrina5.html