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2005-2010 Mustang GT Tech Forum

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Unread 03-21-2008   #1 (permalink)
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Default 2005+ Mustang Fuel Tank Fill Problem and Filler Neck

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Ford Technician has encountered the fuel fill issue on numerous occasions and as a result, a Ford Rep and Ford Engineer were sent out. Technician asked why Ford has not come up with a re-design to address this continued problem. The Ford Engineer told the Technician that in fact Ford did come up with a re-design for the filler-neck and inlet tube which did fix the premature fuel shutoff. The problem is the convoluted inlet tube with the numerous turns and bends. As a matter of fact, if you look under your car (as I did after hearing this), you will see that the fuel inlet hose drops down from the filler neck, goes under a cross member, then back up slightly before reaching the tank. At about the halfway point, the inlet tube actually has to go uphill to the tank! The Ford Engineer explained that the new design involved a complete re-routing of the inlet tube. The re-route involved drilling through into the trunk area (behind fuel door) and run the inlet hose into the side trunk area, then back and down (through trunk rear floor) to the tank…eliminating some turns and the uphill run to the tank. The Engineer went on further to say this “fix” was not rolled out due to the inherit cost of all the retrofits… apparently Finance vetoed the “fix”.

I wanted to post back here whether my latest warranty repairs actually fixed the fuel fill issue. My (and this collective Forum's) quest to solve the premature nozzle shutoff continues. Ran the tank down to ~ 1-2 gallons and tried to fill per Ford's recommendation (slowest auto-fill speed & less than 1/4 tank)... NO DICE... got to 7 gallons and nozzle shut-off.. D^MN! The 1/2 nightmare continues. Even after a new EVAP canister... new canister vent solenoid... new EVAP filter.... successful testing of tank check valve... and other emission system valves, sensors and relays, it's still a one saddle-tank pony. I guess through process of elimination, it appears the Ford Tech and Ford Engineer are correct... it's got to be the filler neck and inlet hose. I've seen a few posts here (and other forums) from folks who said they had their filler-neck assembly "adjusted", which solved the problem. I took a look at the filler neck and can't quite figure out what was "adjusted". Does anyone know what kind of adjustment you can make to the neck? There's a funnel shaped attachment right behind the fuel door inlet, which narrows down and attaches to the inlet hose (inside of the plastic wire-loom tube). How is this adjusted? As I stated earlier, the inlet hose makes a few convoluted turns and at the half-way mark (between inlet door and fuel tank) it actually runs slightly uphill to tank (which I'm sure is not conducive to continuous flow). Appreciate if anyone could provide information to this mysterious filler neck adjustment and exactly how it is adjusted to allow uninterrupted flow and a full tank fill. Thx
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Unread 03-21-2008   #2 (permalink)
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dunno man, these fuel tanks are apparently horrible. I got off work at 2AM... stopped to fill up, ( I was at a half tank ) and it only let me put just over 2 gallons in it. I tried to pump very slow and it just kept stopping. Tried to pump fast, same thing. Its annoying and this isnt the first time it has happened.
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Unread 03-21-2008   #3 (permalink)
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That's really disappointing after all those parts.
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Unread 03-21-2008   #4 (permalink)
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Mine used to do that too, My girlfriend always liked counting how many weird looks I got for having the nozzle / handle upside down while filling up the Mustang.


Ricers generally stared and I just pumped and stared back... it was kinda fun :hihi:
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Unread 03-23-2008   #5 (permalink)
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Bump. Hoping to hear from anyone who had their fuel filler-neck / inlet hose adjusted and exactly how/what got adjusted... Thx
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Unread 03-27-2008   #6 (permalink)
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re-bumping for airtime... to those who had fuel fill problems and solved with filler-neck adjustment. How is filler-neck adjusted to allow for full tank fill?
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Unread 03-27-2008   #7 (permalink)
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http://www.allfordmustangs.com/forum...cons/icon1.gif Worked Great
I found this from some time ago. see what ya think...must work...I need to do this fix also

Tried the fix and worked great!!!
I created a page with details and instructions for others to follow.
I think the culpret is the filter box. Not the lines themselves.
Check it out and let me know if you people have success.

http://ratstangrestoration.com/

Go to the tech pages.
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Unread 03-27-2008   #8 (permalink)
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I copied the above post from an older thread from itxlan. he gets all the credit the way its read above looks like I did it...not me.
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Unread 03-28-2008   #9 (permalink)
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Quote:
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I copied the above post from an older thread from itxlan. he gets all the credit the way its read above looks like I did it...not me.
I may have to give that a shot soon. Mine is getting worse by the day.
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Unread 03-28-2008   #10 (permalink)
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Quote:
Originally Posted by MickMach View Post
I copied the above post from an older thread from itxlan. he gets all the credit the way its read above looks like I did it...not me.
Thanks for posting. Yes, I did see his post. My dealership actually replaced the entire EVAP canister assembly tray (which includes new EVAP canister, canister vent solenoid, and EVAP filter). The filter is the one that itxlan cleaned out. The Tech who worked on my car also blew out lines and checked other sensors. Only thing left is the filler neck. It seems that if the S197 filler neck is slightly askew, the pump will prematurely shut off. I'm trying to find someone (as I've seen posts on this Forum) who had their "filler-neck" adjusted to resolve problem. I'm just not sure exactly what you can adjust on the filler neck?
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Unread 03-28-2008   #11 (permalink)
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Quote:
Originally Posted by doctorq View Post
Thanks for posting. Yes, I did see his post. My dealership actually replaced the entire EVAP canister assembly tray (which includes new EVAP canister, canister vent solenoid, and EVAP filter). The filter is the one that itxlan cleaned out. The Tech who worked on my car also blew out lines and checked other sensors. Only thing left is the filler neck. It seems that if the S197 filler neck is slightly askew, the pump will prematurely shut off. I'm trying to find someone (as I've seen posts on this Forum) who had their "filler-neck" adjusted to resolve problem. I'm just not sure exactly what you can adjust on the filler neck?
I've done some searching and can't find any posts on any forums about adjusting the filler neck.
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Unread 03-28-2008   #12 (permalink)
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Quote:
Originally Posted by stlwagon View Post
I've done some searching and can't find any posts on any forums about adjusting the filler neck.
Here's a few... but no mention of what exactly was adjusted or how it was done:

http://www.allfordmustangs.com/forums/681620-post5.html

http://www.allfordmustangs.com/forum...05-post19.html

http://www.allfordmustangs.com/forums/403852-post7.html
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Unread 03-28-2008   #13 (permalink)
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my wifes car is fine ....mine also gets worse each time I try to fill it
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Unread 03-28-2008   #14 (permalink)
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the dealer in my town just put a new tank in my car. fixed the problem.
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Unread 03-29-2008   #15 (permalink)
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Quote:
Originally Posted by Silver2005in209 View Post
the dealer in my town just put a new tank in my car. fixed the problem.
I've got an 06 (build date 5/3/06) so it already had the 'upgraded' tank from the factory. Ford won't replace tank for this issue if it already has the upgrade. I was hoping someone might know exactly what to adjust on the filler neck (as it seemed to work for a few folks.. see links above) so I can try it, or relay it on to my dealership.
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