My fuel gauge pretty much works the way yours does, JimZ. If it is filled up only to the point where the pump clicks off, the needle doesn't make it to full. Typically it will be down at 1/4 after I've gone about 250-300 miles, depending on the fuel quality and whether it's B99, B20, etc.

However my actual mileage doesn't suffer. I seem to have quite a bit of fuel left after the light comes on.

I should say that when the attendent (OR - not a self-serve state) continues to fill the tank after the pump clicks off, the gauge can make it to full.

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Ralph

1985 300D Turbo, CA model
248,650 miles and counting...