Ooppss, I meant I need a new sender not guage. The guage is only a few months old but the sender was in the tank when I got it. I tested the sender but apparently I didn't do a very good job.
How'd you test it? Ohm it out, or hook it up to the gauge and see what it read?
I think hooking it to the gauge is the best way, because, as has been said here (I think) and in other threads, the whole system has to work together. And what with 40+ years on the wires and other components, they ALL might be suspect.
Then, if they're all "close enough", you might just be able to adjust the sender to work within a range you can accept.
Wouldn't hurt then, to verify that your IVR is putting out the proscribed amount of pulsing power at the proper intervals, check the resistance in both the gauge feed and ground circuits. Then, if they all check out reasonably well, hook up the sender and see if it can be adjusted to fit the system.
I did that to my two stock sending units and they have worked just fine ever since. Probably can't fix every sender that way, but it can work sometimes at least.
I never expected my gauge to read perfectly at every point (it pretty much does though), I just wanted it to give me a reasonable facsimile of Full and Empty. I like it to read just a needle's width above full after re-filling, and two needle's worth or so below empty when running on fumes. That way, even at empty I have a couple of gallons left in the big tank, and about a half-gallon on the small tank, when the gauge hit the empty mark.
I still try to fill up at a quarter tank, but at least I know where I stand when I can't be that choosy.
Maybe give that a try before buying a new sender? Either way though, you're going to have to fiddle with the sending unit. Even a new one might have to be tweaked to make work with your gauge.
Paul