Can't fill up my tank!?

[xardoz]

Help!

I've got an '02 Taurus SEL. Last week, I noticed it was down to about 1/4 tank, which I expected since I track my MPG with the trip odometer. I went to a local gas station and only got about a gallon in before the pump shut off like the tank was full. This happens, of course, so I rearranged the nozzle and tried again. This time it shut off almost immediately, like I was trying to top it off.

I tried a few more times, then gave up and reported the pump to the attendant, thinking it was poorly adjusted.

A couple of days later, I tried again at a different station and the same thing happened. I started to get concerned, but hey, maybe I just got hit twice with bad pumps or nozzles.

Nope. I tried again this morning at a third station and exactly the same thing happened.

I know my gas gauge works, so I'm thinking maybe some twerp jammed something down my filler neck.

I can't see anything obvious obstructing the neck, but before I take it to my mechanic, can anyone think of any other possible reason this would be happening?

[G O R T]

There is a flap at the tank entrance that is sticking. You can stick something down there and free it up for awhile, or just fix it.

[xardoz]

Thanks GORT!

When I open the cap to insert the nozzle, there is a small metal flap right below where the cap bottoms out that is sticking partially open.



When I insert the nozzle, it pushes that flap all the way open. Are you saying there is another flap below that, in the filler neck, that isn't visible from the outside?

And if so, how do I go about repairing it? If I undo the three bolts shown in the picture, will that allow me access to the interior of the filler neck?

[G O R T]

No, the flap is at the bottom of the filler neck where it attaches to the tank.
If you feel frisky, drain the tank and remove it for repair. Not sure it can be accessed in the vehicle.
Sometimes a length of 1/4 to 3/8 hose will poke down to the bottom of the neck and force it open but you have to hold the little metal flap at the entrance open or it grabs.

[G O R T]

There is a chance, if the steel filler neck is attached to the tank with a long section of rubber hose, that you can take the hose clamps off and access it without tank removal. Still the only way to remove or replace the flap is through the fuel pump opening. All you can do is poke at the flap to distort it enough not to stick.

BTW, those 3 bolts allow you to pull the filler neck out of the fender if it is disconnected at the bottom.

[waylowrider]

Hey GORT, Just to eliminate the possibility of someone tampering Zardoz's car, do you think sliding something down the filler neck like a "clean rubbber" coated external bicycle brake or shift cable would work? Slide it down until it stops and mark the depth of penetration. Then do an external measure to see it the cable is going all the way to the tank. The cable would have to be long enough and for a safety factor I would put a big gob of tape on one end big enough so it couldn't fit thru the filler neck opening in case it slips. If they made a small O.D. plastic/rubber coated pipe snake that would be ideal. 1/8 inch plactic brake line would work also I think. Cannot be steel because of sparks and gasoline fumes. I can only speak for myself, but I hate dropping fuel tanks.

[xardoz]

Thanks, everyone. I ended up taking it to the shop. They tried to fix it without dropping the tank, but were not successful, so they're dropping it today. I should have it back tomorrow.

[jfjohn]

I wonder if tapping on the outside of the fill tube with a rubber mallet would have freed it up.

[xardoz]

Wouldn't have helped - the evaporator system assembly on top of the tank was bad, had to be replaced.

$186 plus labor ($200). PITA, but what are you gonna do?