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I may have just figured it out. I plugged the sending unit in, and checked the gauge through full range of motion. Full to empty, it was working great. Then I noticed when I was moving the sender, the pickup screen on the bottom of the unit was spinning to the "downhill side" When it was under the float, it wouldn't quite go down to a quarter of a tank. I think as the fuel was sloshing around in the tank, it got caught under the float, and was stuck there. Hope so,,, cheaper than a new unit, but a pain in the *** to pull off without dropping the tank all the way. Ordered a new o-ring (the old one was leaking) to be in on Tuesday, so will leave it off til then. Will let you know when I put it back on.
If you have the sender removed from the tank, open it up and look inside and make sure the insides look OK.
There is a brass wiper-like thing that glides up & down a piece of material around which is wound a VERY fine wire, that wire eventually wears through and the wire unravels.
BTW I looked in the FoMoCo parts catalog, that sender is not original to that truck, somebody swapped that in.
Rezvani's Latest Post-Apocalytic Monster Is a Ford F-150 Raptor Underneath
Slideshow: Called the Fortress, the 850-horsepower pickup combines Raptor underpinnings with military-inspired features, survival equipment, and a starting price of $285,000.