I guess today is the day for erasing the erratic. Through hours of trying to figure out the gas guage problem, I got pretty good at removing the instrument cluster. This past weekend I was working on replacing some burned out bulbs in the cluster planned on making another attempt at the fuel guage. Not only did some bulbs need changing, there were other items to be checked, the tach sometimes registered zero at idle sometimes it would bounce around, always at idle, the trip set recently jammed and the fuel gauge. I have changed the RPM sensor and cleaned the connectors in the past with no postive results.

Pulled the cluster, unscrewed all of the offending items from the circuit board, cleaned them with a spray electronics cleaner and shot a little silicon at their moving parts. Next, I cleaned the mounting points to the circuit board, the mounting screws are the electical pathways from the circuit board to the guages. I did notice some dirt and dust inside the cluster covers. The copper in the board where the guages mount seemed too dark in color, not corroded but not real coppery either.
The tach works as it should, I figure the resistance from the board to the guage is what the problem was but can't be sure that the cleaning and silicon did or at least helped do trick too.

DanR 94 964 289,000 miles (55,000 on the new engine)
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DanR