Don't know if this applies, but on 1990s minivans, the float arm is held on by one plastic finger. If you pop the arm off, you can bend the metal contact arm so it makes better contact. It was REAL common for the gauge to read properly from full to half tank, then drop to "empty" until it got down to 1/4 tank at which time it would read correctly again.
In your case, the float is most likely rotated down too far to where it's stuck on the bottom of the tank. This can happen when the tank is at a severe angle when you put the unit in. What Jacobandnickolas said about removing the box, and installing the sending unit when the tank is at least 1/4 full will help prevent this from happening again.
Saturday, August 8th, 2009 AT 12:49 AM