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