06 5.4 S/C 4x4, had failing level signal on old pump assembly, periodically drop to no signal, had pressure hicup/airlock couple weeks back so installed the Bosch pump I already had, but now my level only goes between 1/2 to 3/4,somwhat following down with usage and then back up to 3/4 when full? No longer get signal fail, so assume wiring is good. connector appeared ok during replacement. Appreciate any ideas (except drop the tank again).

 

It sounds like the fuel sending unit on the new pump assembly might be acting up or misaligned, especially since the signal doesn't drop completely anymore. If you're sure the wiring and connector are good, one thing you could try is running a fuel system cleaner through the tank in case there's debris causing the float to stick. Otherwise, you might be looking at a calibration issue with the gauge itself. Hopefully, you won’t need to drop the tank again!