It happened to me the other day, and I turned the handle of the nozzle 90ยบ from vertical, pointing towards the back of the car, and it let me fill up sans problem....

 

That's exactly what i'm trying to explain. It's the only way I pump gas now (on the wrong side of the pump) I still need to keep the nozzle upside down but it's working much better this way. Try different gas stations.

 

Good news:
I haven't run into the problem again but I try to fill with the nozzle pulled away from the filler as much as possible.

Some extra good news:
A woman with a brand new Jeep Grand Cherokee was trying to fill up adjacent to my station (on the other side) and I kept hearing it click off. I originally thought she was trying to top off her tank as much as possible until I realized it must be the same problem as our Stangs. I told her to fill up with the nozzle upside down and she gave me a WTF look but tried it and it never clicked off for her. The good news is that this isn't just isolated to the Mustangs. I *BET* that this is due to some stricter emissions regulations that require reduced evaporative emissions of gasoline tanks, so they restrict the fillers and can cause premature click-offs when the conditions aren't right.

 

I'd bet you're right! If you get under your car, you'll see the hose leading from the filler to the tank is a little bitty ****er!

 

I had the problem with the first tank. Haven't had any since.

 

This is an annoying problem. Ford must fix it.

 

I just ran into this problem again. What's strange is that when I'm filling the tank with the gas nozzle, the trigger physically feels different in the upright position versus sideways and upside down. It won't click off by itself when filling it sideways or upside down so I have to know when to stop filling it or else I get gas all over the side of the Stang.

I cleaned the evaporative emissions air tube and even wrapped a mesh filter on the intake to prevent debris and spider eggs from clogging it. It didn't help so this obviously wasn't the problem. The only things that remain, as far as I can tell, are:

1). Inadequate gas tank venting
2). Fuel filler tube needs to be re-routed to allow for faster draining

 

Happens to me all the time. I hate it.

 

Yeah, happens to me about 1 in 4 fill ups, even when going slow sometimes.

 

I have several gas stations in the area where I know that it will not cause me any problems...but then I got to thinking that if I should take trip somewhere, then I would probably have to make several stops in order to find a station where I won't have problems. I also make it habit never to get below a half tank (and this should help, especially on a trip).

 

How low were you when you filled it up?
I never let mine get below 1/4 of a tank. Usually when the gauge gets just past the half full mark, I start looking for some good prices on gas.

 

I had this EXACT same issue. Had no idea others were having it too.

 

Very, very annoying.

 

I never let my gas tank run low but I found that this doesn't have a significant impact on this issue for my car. I've tried to fill at 3/4 of a tank and had it spit out gas, and the most recent occurrence was with about 5/16 to 3/8 of a tank full.

I find this to be a potential safety issue.