Three things: when you did your direct wiring test you would have needed to have a ground from sender to gnd and from case of meter to gnd. The case of the meter needs a good gnd also. Not the two terminals but the case. Like you said one term is hot and one is sender. Second thing: Always check the system before installing a new component so you know all is well and that the new component did indeed fix it, right now you don't know that for sure. Third: IF, IF, IF you did the testing correctly with grounds, then the component that is common to both tested systems is the gauge. Which means that the gauge is BAD! Two different senders with same test wiring and same gauge means gauge is BAD! It also probably means your original sender was OK. Keep the sender, it can be used to test other gauges, such as the temp gauge. The rheostat sends a variable resistamce signal to any gauge that uses a variable resistance signal, I.E. temp gauge.
P.S. If your tests were not "pure" and did not have proper hookups and grounding, then retest all or you will go crazy and start shooting things with a shotgun. You must start with known good components before installing in truck. And just because they are new does not mean the Chinese guy built it right. thanks for your words on the DQ.
Last edited by bartamos; 08/21/2011 8:04 PM.
