Correct. In a few cases where I have been assisting troubleshooting gage woes the above is the case. EVEN with brand new tank brown replacement wire assy's. The female connector that slips over the stud lacks sufficient tightness to maintain consistent electrical contact and continuity. Some corrective actions are; clean stud on sender with contact cleaner and polish brass with craytex or equal abrasive, Same with female connector and also pinch the barrel of the female connector with pliers but not to much & test fit, I use silicone grease or better yet T&B conductive grease Koper-shield (just a dab) before making the connection.

Additionally I built a "SIMULATOR" tester to validate the body & dash & gage wiring by installing a hand held 0-100 ohm potentiometer to dial a gage where you can sit in the car and run the knob up and down and watch the gage repeat.

JIM

Great ideas, thanks to all who have responded!

Bill what I was talking about is where the stud goes thru the sending unit there is a insolator and a strap that goes down to the sender resisitor. The connection from the stud thru t6he mounting plate goes bad. There is a push clip that holds it together you take it apart and clean it

I will give that a shot, John....thanks!

OK, it's definitely a sending unit problem. I bought a repop sending unit and it arrived today. Hooked it up in the trunk of the car and moved the float through its range of motion, and the gage reads perfectly.....'Empty' when the float is at its lowest point, and 'Full' when it's all the way up.

Of course, since we are talking about repop parts, nothing is quite right....all appears good except for the ground wire. The ground wire is connected to the sending unit body pointing in the wrong direction - AWAY from the direction it should be going. Plus, the wire is about 4" shorter than the original one, and since one would need to use additional wire length in order to route the wire in the proper direction, that makes it effectively shorter yet. I mean, really, all the engineering involved in making this thing otherwise a very good copy of the original and you screw up two SIMPLE details like these? No wonder so many repop parts have a bad reputation.

One American dollar says if you contact the repop company about their short comings,they'll reply,"You're the first person to tell us this Mr.Pritchard."

I would bet that same American dollar that you are 100% correct, Rick!

Well, I tried John's suggestion about taking the hot wire connection apart to clean it, but it seemed like I would destroy the whole works before it would come apart.....so I took Rich's suggestion, and sent it off to John Wolf & Company in Willoughby OH for restoration. Got it back today and wow.....it looks like new....

Hooked it up in the trunk (as I detailed in a previous post in this thread) and it works perfectly. And whaddayaknow, the ground wire is long enough to connect to the proper location on the car. They also reused the original ground wire terminal end so the appearance is as close to OEM as possible. Now all I need to do is order a 'sock' type filter for the end that goes in the tank and it will be ready to go back in the tank.

I found this thread to be helpful on my 69 Z:

http://www.camaros.net/forums/19-ele...n-69-pace.html

mine had issue where the ribbon connector connected to stud that went through the sender to the wire figured since had at worst to buy a new sender, so I bent the ribbon and got continuity and been fine since fixed no cost but my time

I had a very large reproduction parts house tell me that one time so I directed him to a Team Chevelle thread where they were talking about the same complaint as mine and with their product and there were at least 10 complaints exactly like the one I was talking about. He did not have much to say after that but was still not willing to make good on it. I said they could either stand behind their product or I would add to the thread on Team Chevelle. The worst part was I spent at least $50k a year with this company, every year, which I no longer do. Their loss.