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Originally Posted by pjmoreland
It does sound like your sender wire has continuity to the gauge since you are measuring voltage on it. Here are some thoughts:
1) Are you certain you are touching the sender wire to a good ground?
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I'm using the door latch, which seems to be pretty solid/consistent with the test light, but I admit I could be less lazy!
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2) Is the metal case of your gauge cluster grounded adequately?
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Probably the next step, but I'd assume if it wasn't grounding it wouldn't power up at all... No?
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3) You might learn something useful by disconnecting the gauge from the flexible circuit board so you can measure the internal resistances of the two windings inside the gauge. Maybe the winding that pulls the needle toward Empty is fried. Maybe the ceramic resistor on the back of the gauge is bad.
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That was my next -next step, just trying to rule out things that involve so much pulling apart before I get into it.