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It really sounds to me like there is corrosion in the rheostat that is slowly working itself out as you drive/ use the truck. You already tested the wiring to the sending unit, there really isn't any other place for the problem to be.
The correct way to fix this would be to put in a new sending unit; but they are a PITA to remove and replace without dropping the tank, which raises its own problems (33 year old filler and vent hose comes to mind). If you do get a new sending unit, I recommend getting a new gasket for the flange instead of trying to reuse the old one.