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Greg, it's really hard to imagine that NONE of the threads on the sender fitting cut thru the tape and made contact with the head. Even if you used a LOT, chances are it would have cut thru somewheres. And if by chance it didn't, it seems to me that all you would have to do is crank it down a little MORE and it WOULD cut thru.
The other thing is that you didn't mess with anything fuel related, so THAT guage going wonky on you wouldn't add up as being caused by the head swap.
All that said, I HAVE heard of the two guages getting fussy at the same time, but that was on an FJ60, so you might want to research in THAT forum to see if there are any good suggestions on what to check.
Best
Mark A.

The other thing is that you didn't mess with anything fuel related, so THAT guage going wonky on you wouldn't add up as being caused by the head swap.
All that said, I HAVE heard of the two guages getting fussy at the same time, but that was on an FJ60, so you might want to research in THAT forum to see if there are any good suggestions on what to check.
Best
Mark A.