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What would make my fuel gauge on a 1997 Astro van read full most of the time but never get below seven eights tank no matter how much is in it?

The most likely culprit for your 1997 Astro van's fuel gauge consistently reading nearly full is a faulty fuel level sending unit. This unit is located inside the fuel tank and is responsible for sending a signal to the gauge indicating how much fuel is present. If it's malfunctioning, it's likely stuck at or near its maximum reading.

Here's a breakdown of why this is the most probable cause, and other less likely possibilities:

* Fuel Level Sending Unit (most likely): These units are prone to failure over time, often due to corrosion, debris in the tank, or simply wear and tear. A stuck float or a broken potentiometer within the unit will prevent it from accurately reporting the fuel level.

* Gauge Cluster (less likely): While possible, it's less probable than a faulty sending unit. A problem with the gauge itself is usually indicated by erratic readings or complete failure, not consistently high readings.

* Wiring (less likely): A short or break in the wiring between the sending unit and the gauge could cause inaccurate readings. However, a short usually leads to erratic behavior or no reading at all, not a consistently high reading.

* Ground Issue (less likely): A poor ground connection in the fuel level circuit could potentially affect the gauge's reading, but it's less likely to cause a consistently high reading.

In short: Start by suspecting the fuel level sending unit. Replacing it is usually the most cost-effective solution, and if it's truly malfunctioning it is the repair that will fix the problem. You'll likely need to drop the fuel tank to access and replace the unit – a job often best left to a mechanic unless you're comfortable working with fuel systems. Before doing so, you could try disconnecting and reconnecting the fuel level sending unit electrical connector, but that rarely produces a lasting repair.