I, like many others on this Forum, have been plagued with the dreaded fuel fill problem. Mine started from day 1 (the day I bought the GT, the dealership tried to fill tank and only got ½ tank filled… we all assumed it was their pump). I’ve had my GT for 18 months now (14K miles), and run into the fill issue about every 3rd or 4th fill-up. Each time I ran the tank down to the “50 mile” warning, and when filling, set pump at slowest fill speed. When issue does surface, I can only get ½ tank in before pump shuts off...and fuel is all the way up in the filler neck. I’ve even crawled under the car at station and tapped on the saddle tanks… finding the left saddle tank filled while the right saddle tank sound like the tin-man (empty). OK, now on to the news you can use. I took car in yesterday for the RCM Module (airbag) reflash. While there, I told them I’ve had it with the fuel fill issue. I was really impressed with the dealership as they really owned up to the problem (stating they had run into a number of these in the last 2 years) and methodically trouble-shot the problem. Here’s an excerpt of the work-order notes:
“Using IDS and ran EVAP test. Vehicle pass test. Tried to add gas and monitor fuel tank pressure. Started out at 2.6 volts then it jumped to 3.5 volts to HIGH. Disconnect each line one by one to check for blockage. Found Charcoal EVAP Canister plugged. Replaced Charcoal canister assembly. Retest OK. Also removed fuel filler neck and inspected, OK. Inspected check valve in fuel tank, OK.
Note to Customer: This vehicle is equipped with SADDLE style tank which has two sections. Vehicle will not fill up completely unless the tank is below ¼ tank and unless you are using the “autofill” function on pump on the lowest flow setting”.
So, based on their notes, it appears while they were measuring the pressure in the tank, they witnessed a voltage jump. Assuming this means it was requiring additional current to attempt to ‘fill’ or force air out of the right tank via the EVAP system… thus concluded there was a slight obstruction (a.k.a., charcoal EVAP canister). They added new EVAP canister assembly, and I’m happy to report that today, while nervously adding fuel, I was able to fill to 100% capacity!
They also stated that they eliminated other possible concerns such as:
Fuel Filler Neck (visual inspection and performed adjustment)
Fuel Vapor Control Valve (electronically tested and passed)
EVAP Canister (failed and replaced)
Fuel Tank Pressure (FTP) sensor: (electronically tested and passed)
Canister Vent Solenoid: (replaced with the EVAP Canister)
EVAP Canister Purge Valve: (electronically tested and passed)
It appears there are many potential failure points in the Evaporative Emissions system which could cause the saddle tank fill issue… in my particular case, looks like it was the EVAP Canister and/or Canister Vent Solenoid (both replaced). The Service Manager did share with me up front that these types of issues can be difficult to resolve as FORD requires test failure documentation before authorizing part replacements (under warranty). My hat’s off to Folsom Lake Ford as their Tech was able to produce this failure (blockage) through the tank pressure test.
Anyway, sorry for the dissertation, but wanted to provide this to those still plagued with the fuel fill issue. Perhaps your issue is also tied to a partially blocked EVAP Canister and/or intermittent Canister Vent Solenoid. I guess only time will tell if in fact this did fix my issue (as I’d feel better after a half dozen successful full tank fills at various stations). Hopefully, based on what they found, looks like this may have solved the Pony feed issue.
Sorry... looks like some formatting issues... here's the 2nd half reposted:
So, based on their notes, it appears while they were measuring the pressure in the tank, they witnessed a voltage jump. Assuming this means it was requiring additional current to attempt to "fill" or force air out of the right saddle tank via the EVAP system... thus concluded there was a slight obstruction (a.k.a, charcoal EVAP canister). They installed the new EVAP canister assembly, and I'm happy to report that today (while nervously adding fuel), was able to fill to 100% capacity!.
They also stated that they eliminated other possible concerns such as:
(1) Fuel Filler Neck (visual inspection and performed adjustment)
(2) Fuel Vapor Control Valve (electronically tested and passed)
(3) EVAP Canister (failed and replaced)
(4) Fuel Tank Pressure (FTP) Sensor: (electronically tested/passed)
(5) Canister Vent Solenoid: (replaced with EVAP Canister)
(6) EVAP Canister Purge Valve: (electronically tested/passed)
It appears there are many potential failure points in the Evaporative Emissions system which could cause the saddle tank fill issue… in my particular case, looks like it was the EVAP Canister and/or Canister Vent Solenoid (both replaced). The Service Manager did share with me up front that these types of issues can be difficult to resolve as FORD requires test failure documentation before authorizing part replacements (under warranty). My hat’s off to Folsom Lake Ford as their Tech was able to produce this failure (blockage) through the tank pressure test.
Anyway, sorry for the dissertation, but wanted to provide this to those still plagued with the fuel fill issue. Perhaps your issue is also tied to a partially blocked EVAP Canister and/or intermittent Canister Vent Solenoid. I guess only time will tell if in fact this did fix my issue (as I’d feel better after a half dozen successful full tank fills at various stations). Hopefully, based on what they found, looks like this may have solved the Pony feed issue.
great info! I have never had this problem affect my stang, but I was always very curious what the problem could be. I hope this is a blanket fix for everyone with this problem.
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2005 Mustang GT M5 -I reject your reality and substitute my own-
Oh great, so what do I do if I have no warrantee, am in the UK and no Ford dealer will touch it!
Is it still the case that Ford wont supply these parts without proper testing being done?
Ahhhhhhhhhhhhhhh i cant live with this problem any more!
just an FYI:
there is a revised fuel tank and vapour managment valve that should help wth the re-fueling issues on 2005 to 2007 ALL Mustang's
the tank part # is 8R3Z-9002-A and a revised fuel vapor canister valve part # is 7R3Z-9D653-D
At this point I only fill up at two stations near my home...one is a BP and the other is Shell...most of the other BP and Shell Stations within a 4 mile radius of my home give me fits.
Probably lives in a state where you are not allowed to pump your own fuel. 50 miles west of me sits the People's Republic of Oregon where is is illegal for you to pump your own fuel. The lawmakers in that state must figure it takes a degree in petrochemical engineering to squirt gas.
just an FYI:
there is a revised fuel tank and vapour managment valve that should help wth the re-fueling issues on 2005 to 2007 ALL Mustang's
the tank part # is 8R3Z-9002-A and a revised fuel vapor canister valve part # is 7R3Z-9D653-D
Any idea what the difference is between the 7R3Z-9D653-C and the 7R3Z-9D653-D ? The dealer replaced by EVAP canister with the "C", so wondering if I'm still in for problems.
hey doctorq, my car is at Folsom Lake Ford right now, with the same problem, who did you talk to there? they are telling me my tank is the new design, theat i have to deal with it. would love find out who you talked to. its not what you know, but who you know...by the way, did they charge you for the canister and solenoid or were you under warranty? thanks in advance. Rich
hey doctorq, my car is at Folsom Lake Ford right now, with the same problem, who did you talk to there? they are telling me my tank is the new design, theat i have to deal with it. would love find out who you talked to. its not what you know, but who you know...by the way, did they charge you for the canister and solenoid or were you under warranty? thanks in advance. Rich
Rich: my Service Advisor was Gary Goings. They also gave it to their #1 Tech (Tim) to trouble-shoot. They replaced the Canister Assembly (part# 7R3Z-9D653-C). Someone posted above that Ford has a new EVAP Canister to address this problem now (part # 7R3Z-9D653-D). If this is correct, it would be nice to know what the difference is between the "C" and "D" parts. If it was redesigned for the fuel fill issue, I hope I don't run into the problem again, being they just replaced the "C" version instead of the "D" design. Everything was covered under warranty (only have 14K miles and 18 months on the 06GT). Post back (or PM me) as I'd like to know what they did for you to resolve... and if in fact it solved your fuel fill problem.
Fuel Tank Fill Problem Resolution 
