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when i ground out the gas gauge with a test light the light pulses dimly and will only go up to 3/4 of a tank is it the gauge or am i just robbing that little bit of power needed to peak out the gauge by running the light?
the fact that it only goes up 3/4ths of the way is concerning would it be because the test light is robbing the power?
It only goes up 3/4 of the way with a test light in the circuit because the impedance of the test light limits the current through the gauge, which limits the swing. Like I said, everything he says sounds normal. But there's not much value in doing what he's doing.
The correct way to test the gauge is to put it all back together, then ground out the lead going back to the sending unit, out at the sending unit itself. If the gauge doesn't peg FULL, make sure there is a good ground out there (sometimes you have to run a jumper wire to sheetmetal under the bed). 99.99% of fuel gauge problems are out at the sending unit area, whether it's a bad sending unit, float, or bad ground at the frame.
If you're trying to truly calibrate the gauge, you should use 10 and 70 ohm resistors. That's another story.
I still don't know what the actual problem is, so I'm not really sure how useful I can be here.