Here are a couple of videos on the fuel gauge: Basically, you're not testing the gauge properly. To bench test the gauge, you need to connect 12VDC+ to the green wire, ground the black wire, and run the yellow wire through a resistor that is grounded on the other side. You should have 12VDC+ to ground at the green wire coming into the gauge when the key is in ON. There is a voltage regulator in the gauge as discussed in the videos above, and the yellow wire comes off the regulator and goes to the fuel level sender. You should measure voltage to ground at the yellow wire at the gas tank with the key in ON. When the key is first turned to the ON position, you should see about 12VDC to ground at the yellow wire. As the voltage regulator warms up, you will see the voltage fluctuating. You can also ground the yellow wire at the gas tank for a short period of time and have someone see if the needle moves on the gauge.