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The tach filter IS required and is likely your problem, since you have repaired the board. The filter takes out any unwanted spikes from the tach signal (anything other than the signal pulses). Now that you have bypassed it, many 'false' tach pulses are affecting your tach reading. The fact that the reading is stable indicates that you fixed the board problem, but the filter is also bad. You can either buy one or make one (with a few dollar$ worth of Radio Shack parts). Search the CF Archives for info on that subject.
I’ve seen on original filters where the wires going in and out are broken and just sitting in the hole making random contact with the filter. This would cause you intermittent working tachometer and might be fixable if it’s an original filter.
Sometimes you can put a drop of solder in there and it will reconnect the wire. Food for thought and it might keep you from buying one.