Fuel Gauge Inop

Fellow "A" body maintainers,
Racking my cranium trying to figure out this fuel gauge anomaly. Needle moves ever so slightly to just above the "E". Here's what I've accomplished:
- Installed new tank/sending unit and got that slight movement above "E"
-grounded power lead at tank and gauge will peg out to full and return to empty. That tells me wiring up thru the instrument cluster is good.
-Removed sending unit. Rheostat ohmed good from empty to full. 3ohms to 84 ohms
-With unit out of tank and grounded I manually moved float and gauge read empty to full.
-Re-installed sender and grounded as per Mopar and with half tank fuel had no response to gauge movement.
-tried all different variations placing ground in different locations. All continuity checks were good.
-Ensured I had my engine to firewall ground intact.
-Ensured cluster was grounded to dash.
- Manipulated ignition switch to see if any help but none.
-Tried a second sending unit....same result
-Just for giggles, I replaced the volt limiter on cluster...same result.
-I turned the sender upside down in the tank and it read full on gauge. Re-installed it right side up and no reading.
- Could it be a baffle in the tank is installed incorrectly? Need you guys to help me right the ship.


Here's one you may not have checked..

Did you check to see if the gauge needle is being interfered with as it is trying to deflect to the right?

If you had the cluster apart , when you reassembled it, you may have inadvertently squat the plastic housing or the metal graduation plate into the pointer and stopped it from moving.

I had exactly this happen with my temp gauge and only found it when in desperation, I completely disassembled the cluster.

Its always something simple that causes strange problems like this. Unfortunately, they are only simple after you find the solution!!!

Hope this helps...