Fuel Gauge not accurate

ValiantHardtop said

My new fuel sender is a bit panicky too... Hits empty with 20+ litres still in the tank...

From looking at it before it went in, it seems there are tangs on the unit that act as stops. Perhaps pulling it out and bending the tangs might help. I'm leaving mine as it is, leaves a (massive) safety margin

Click to expand...

About that..
The original sender/pick up assembly was the longer straighter shown below. That float would bounce against the bottom of the tank and wear a hole in the float eventually. The redesigned sender for later models doesn't allow the float to touch the bottom and is the only type reproduced.