Join Date: Apr 2009
Location: Mid hudson valley of New York
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Always look to the last thing that you screwed with! If the gauge was working properly before you took the cluster apart, and it's stuck on full after you put the cluster back together, it is NOT likely that you have a stuck float. It is very likely that you screwed something up in the cluster.
Let your rear seat back down, and lift up the carpeting in the trunk (might have to pry out a plastic plug to get it loose). Looking into the trunk from the back seat, on your left side (passengers side of the car) you will see the wiring that goes to the float. There is a plug there which you can separate. That will disconnect the float from the fuel gauge.
If you turn the car on now, with the float disconnected, the gauge should read empty. If it goes to empty with the wiring disconnected, then there is a problem with the float. However, if it continues to read full, then the wire between that connector, and the gauge is shorted to ground somehow. I'd very carefully look over the connections and wires at, and near the cluster to find the problem.
I hope that helps!