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Ford Explorer Community - Maintenance - Modifications - Performance Upgrades - Problem Solving - Off-Road - Street
Explorer Forum Covers the Explorer ST, Explorer Sport, Explorer Sport Trac, Lincoln Aviator, Mercury Mountaineer, Mazda Navajo, Ford Ranger, Mazda Pickups, and the Ford Aerostar
Check the obvious, connections, corrosion etc, first. There is an anti-slosh module in the gauge pod that affects how the gauge reads. It's a small circut board in the back of the gauges. I have been wanting to design a way around this and make a true gauge, but have never had time. Also it sux, but your new sending unit could be bad.
I had two trucks in your situation. One the gauge worked but pump went bad, second gauge wouldn't work. Both got Bosch pumps from rockauto and neither have a working gauge. I just fill up every 200 miles. I'm getting ready to do another pump on a third vehicle and I'm curious if I get the same result. I bought a different brand pump assembly.