I seem to have a lot more fuel in the tank when it's "near empty" too. I checked my sender with an ohm meter before installing and it was pretty darn close to spec at full and empty. But I also had to bend the pickup slightly because it interfered with the bottom of my brand new tank - so who knows? I can pump 5 gal in when reading 1/8 or so and get a reading of 3/4 or more (Autometer gauge and repop sender).
