My temp gauge doesn't work so I bought a new sending unit, but it seems like the threads don't match, it just doesn't want to go in there! The thread looks clean, no gunk in the way. The old unit is the same size as the one I bought, but it looks like some of the threads on it were filed down. Should I rethread and try to find a unit to fit the new threads? Or try a smaller unit?
Kills me that this tiny little thing is driving me so crazy!

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'70 Plymouth Duster 225
"A girl can fix stuff too! (sometimes.)"

If its the same size then thats that - these senders are NPT... one size up or down is significantly differnet so you would know if it were the wrong one.

Sounds like someone may of done a poor job of retapping the threads previously, and when the forced your previous sender into it they buggerd the threads up, hence whey seem filed.

You can try buying the proper tap and cleaning up whats left, or you may have to go one size up, drill, tap, and install a brass bushing fitting (ie, 1/2" male threads on outside, 1/4" female threads on inside, hardware store item in brass fittings section)