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Most of the aluminum cells I have used had a roll over check valve installed in the fitting where you attach the vent line.

The old stuff just vents into the frame rail

Gas will go bad within a couple months,if it was in the filter and carb my guess is varnish.

Is the new sender accurate?

All the new china senders read that way and even the ones from mexico that are supposed to be good read bad.I just installed a new one and it reads sorta like yours.10 gal reads empty,15 gal reads 1/4 and goes to full when full.

Just drop the tank,its a pain the get sender gasket and lock right working on your back.I just siphon the gas out before I drop them.