Fuel gauge/sending unit issue
#16
In both of your cases, the fact that actuating the float arm by hand produces satisfactory results with all electrical connections left as they would appear in the truck, exonerates anything electrical. Period.
If the only thing that changes once the sending unit is in the tank is the fact that the gasoline itself is responsible for actuating the float arm instead of your hand, yet the results are not equivalent, then either the float arm is bent, the sending unit is geometrically incorrect (wrong part), or the float is punctured.
If one of those three is not the culprit, then there's more to the story, or something was not made clear in the problem description.
If the only thing that changes once the sending unit is in the tank is the fact that the gasoline itself is responsible for actuating the float arm instead of your hand, yet the results are not equivalent, then either the float arm is bent, the sending unit is geometrically incorrect (wrong part), or the float is punctured.
If one of those three is not the culprit, then there's more to the story, or something was not made clear in the problem description.
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