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I have lived with this for a long time. But if something can be done, someone here might know. When I fill my tank, the guage indicates over full. After driving 100 miles it goes down to full. After another 100 miles it reads 3/4. another 100 miles shows 1/2. The next 100 will drop it to a little under 1/4. It than will run out of gas soon still reading 1/8 of a tank. Do all Bronco's gauges read like that? It would be nice if I could make it read lower on all settings. Is their any adjustment. How about a resister wire put inline. I'm guessing the sender sends ground to the guage. I dont know.
I usually fill up when I'm under 1/4, but I also know that when over 400 - 500 miles (city - hwy) I'm getting very close to runing empty, and since I often drive out in the boonies where there may be no station for quite a while, I always make sure I have plenty of gasoline. (and I know where the gas stations are)
You can most certainly put in a resistor or two to fine tune your gauge, but why bother? Just learn when it's a little under 1/4, you really need to fill up.
You can replace the sender and pump, but that's lot of work.
Myself, I find that it is just as ez to keep the top of the tank full as it is the bottom, but my Bronco only goes 200 miles a tank, I try to keep it from going down to far.
Could be the sending unit, as when the tank gets down to about half, the gas flys around in there and beats the crap out of the sending unit. Ford probably should have put some sort of baffle or partial divider in the tank to prevent that. A fuel cell is an even better solution. Of course the stock gauges are all very inaccurate anyway. You sound like you have at least some experiance with electrical, so you may want to consider getting some aftermarket gauges. You could just add them onto the A-pillar or get a little more in-depth and replace all the original ones with something a little more custom.,