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When driving on trips I fill it to the top on my 818. If I know it's going to sit before I fill I won't. I know about expansion, but do we forget our tanks have vents for this reason. They knew a soldier wasn't going to stop at the strainer, nope, he was going to over fill it.

You should be able to see where the strainer and the filler neck meet. Definitely don't want you to break anything.

Most of the time it's a grounding issue or as in my case it was grounding and the sending units were rusty.

Yeah they tend to stick if never messed with. Forewarning, you will smell like diesel when done messing with it so you might want to wear some gloves, especially if the fuel is in the strainer. TM extract.

The strainer is removable, use to pull mine all the time when filling up in Iraq.

Get a paint stick and when your gauge shows 1/2 see where the level is, and the same for 1/4.

How did you verify it was empty? Never trust a military fuel gauge. I changed both my sending units on my 818 but still carry a home depot paint stick to verify.