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If the fuel pump (right side of tank) or the fuel filter (left side of tank) - both with a level sensor - are not "clocked" correctly in relation to the fuel tank then the arm of the level sensor will hangup on the hoses inside the tank preventing it from ever reaching the bottom of the tank. There is a little arrow cast into the top of each assembly and a casting line on the tank that have to line up with each other. If they are off, it sound like the arm of the level sensor is stuck on the lines. (9 times out of 10, if the left side thats the problem). Most of the time this happens after the unit is replaced and installed incorrectly, but I have seen a few times where over time the locking ring loosens up causing the unit to rotate out of place.
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