Most of those senders are simply a coil of resistance wire with
a wiper contact, a simple rheostat. They aren't to sturdy and
can be easily damaged. If that's visible or accessible double
check to make sure the coil doesn't have a break in it. That's
a very common problem with the rheostat's for the dash lights.
dg
Good point Denny,as I say,the sender works perfectly outside the tank,i'm beginning to suspect the float itself,it's a closed cell foam and seems to be 'heavy'??
I'm wondering if this is just another ethanol based problem,if you squeeze the float it oozes fuel,gone porous perhaps?
The place where I buy my unleaded use a 5% mix,so,if in fact this is the case,the damage has already been done.
I threw out my original unit with the white plastic type float,I could have retro fitted it to the one I have just now to eliminate that possibility.
Hindsight eh?