Gas tank Filling Problems On A 2005 Mustang

2005 Mustang Gas Tank Filling Problem

2005 Mustang Gas Tank Filling Problem

Question Re: Gas tank Filling Problems On A 2005 Mustang

Can I replace the vent tube on the gas tank? Or do i have to replace the the entire tank assembly?


Boy, have you opened up a can of worms!

I'm going to spend some time on your question, because chances are, the vent tube isn't your actual problem.

Gas tank Filling Problems On A 2005 Mustang are very common. And to some extent you can also have them on the 2006 and 2007 models.

The real issue with the 2005 Mustang V6 and V8 powered GT cars, starts with filler tube angle and escalates from there to needing to replace your gas tank.

I've been fortunate in not having had this issue on our 2005 Mustang convertible, but it's very common. And I've seen the very same problem in the F350 diesel trucks from the mid 1990's.

Fuel Hose Problems

Slight differences in the length of the filler hose from the filler door to the tank, or the way it was mounted can cause virtually the same issue.

There is very little clearance for the filler hose to the saddle tank, so even slight differences in angle of the hose can cause problems for filling, which will appear to be a vent hose issue.

For most Mustangs, that equates to trouble filling the tank to full, or having it click off numerous times before being able to fully fill the 2005 gas tank.

Evap Canister Partial Plugging

If your evaporative control canister or it's components have any clogging issues interfering with the canister vent solenoid's proper operation or you have a plugged EVAP canister filter, it can tell the fuel tank pressure sensor that there is excessive pressure (meaning the tank must be full).

Gas Tank Design

Early 2005 production has an issue (design I assume) that can cause difficulties in filling up the tank without issue. There is only one fix for this, but it is covered by Ford under a TSB, which is detailed below.

TSB (Technical Service Bulletin)

This became a big enough problem that Ford issued a technical service bulletin, which details a fix for the problem that will be provided at your local Ford Mustang dealer, which I will reprint below.

Note: There are issues dealing with early 2005 Mustang gas tanks separate from the later 2005, as well as 2006 and 2007 Mustangs in this bulletin. You may still need to
look at the possibilities listed above, to fully get a satisfactory result.

Here is the TSB for Gas tank Filling Problems On A 2005 Mustang:

Fuel System - Difficult Fuel Fill/Nozzle Shuts OFF

TSB 07-21-12



2005-2007 Mustang

This article supersedes TSB 06-3-13 to update the vehicle model years.


Some 2005-2007 Mustang vehicles may experience premature automatic shut off of the fuel fill nozzle. Several variables, including variations in fuel pump nozzles, fuel flow rates, and fuel flow pressure may result in the premature automatic shut off of the fuel fill nozzle making it more difficult to fill the fuel tank.

The automatic shut off in the fuel fill nozzle may trigger multiple times after delivering several gallons of fuel or it may trigger repeatedly when attempting to establish fuel flow into the fuel tank.

The latter concern may be more common when adding fuel to a vehicle where the fuel level is at or above 1/2 full.

ACTION: Refer to Service Procedure.


On 2005 Mustangs vehicles built before 4/26/2005 that experience premature automatic shut-off of the fuel fill nozzle more than occasionally may benefit from replacing the fuel tank with a revised design tank per TSB 05-15-12.

The revised design fuel tank may reduce the occurrence of premature automatic shut off.

On 2005 Mustang vehicles built on or after 4/26/2005 and 2006-2007 model year vehicles were built with the revised design fuel tank.

As a result, replacing the fuel tank on these vehicles will not change the occurrence of automatic fuel fill shut off.

Occurrences of premature shut-off may be resolved or improved by using a different filling station fuel pump.

Unauthorized modifications and/or alterations to the vehicle are not reimbursable under warranty and are not recommended for this issue.


WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage

IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.
9002 42

Bottom Line:
Use this information first, and see where your car fits into this TSB information and see your local Ford dealership's service department.

Quote the TSB number and see what happens. If you don't have satisfaction, you can certainly push them to look at the other issues outlined above.

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Comments for Gas tank Filling Problems On A 2005 Mustang

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pi**ed off pony
by: kitt90

i bought my 05 pony brand new , within 2 months I started having problems with filling up the gas tank.

1st I slowed the gas rate delivery by gently squeezing the nozzle this worked .,for a bit. Then I went to turning the fill nozzle a full 180 degrees (upside down) this worked too for a while. I took my pony back to the horse trader (the Ford dealer) where I got my stead (my Mustang) from. I was told even though I had purchased saddle protection in the form of an extended warranty, the problem was not covered for the 1st $200.00 of the repairs.

Really? I'm sort of usde to horse cr*p but, this was pure bull. So now when I go to provide my pony with something for its tummy ( putting gas in it ) I get about 1 gallon in before it tosses fuel back at me down the side of it and all over the ground .

Now I have found out there is no fix for this from the horse trader or the company he represents. I'm thinking I should take my lil pony to a horse doctor or trade it in and an old geo metro a mini cooper or a fiat.

Hey kitt90

Sorry to hear you figure you got roped into a big pile of pony car do do.

I'm going to blow the lid off the fuel shut-off and slow rate gas tank filling problems for your 2005 Mustang.

This is a very common issue with these cars and until a while back, your dealer's hands were tied. Ford can tell me otherwise, but until I have heard the official word, the dealer's problem was lack of a fix for your problem due to the cost of a redesign in the tank/and or tank venting.

One Fix For Gas Tank Slow Filling or Gas Pump Premature Shut Off Problems

From what I have seen, one major issue is related to two parts of the same system. First, the tubes from the gas tank vent are a big convoluted pile of snakes, with too many twists and turns and a filter canister that can easily become clogged with dirt and dust, preventing the escape of air when fueling which in turn tells the pump that your tank is full.

Unfortunately I don't have the 2005 Mustang convertible any more, or I would post some pictures to follow this explanation. But what you see should be pretty much obvious when you get into it.

Look under the rear of your car. You will find a protected wire harness entering a fairly big black cover that has several good sized holes cut into it.

Step 1.
Disconnect the wiring harness clip from its mount and remove the tape if it still has it attached.

Step 2.
Open the clamp that secures the two hoses ( 1 metal and 1 rubber) to the frame and pull them away from the clamp.

Step 3.
Following the hoses towards the passenger side, you will find another clip. Pull the hoses away from this clip retainer.

Step 4.
Remove the two bolts and nuts that secxure the black cover to the underbody and allow the assembly to angle down to the ground, exposing the assembly of hoses and vent filter.

Step 5.
Locate the vent hose that is attached to a plastic box and another hose fitting at the opposite end. This is the tank vent filter.

Using compressed air, blow out the filter. This has fixed a number of 2005 Mustang gas tank fill problems.

Second Fix (Dealer Service Bulletin)

If your 2005Mustang was manufactured before April 6, 2005 there is a TSB (Technical Service Bulletin) from Ford related to this issue and it requires a trip to your local dealership for a new gas tank!

See TSB 05-15-12

TSB 05-15-12

addressed the problem and says that the issue is eligible under provisions of New Vehicle Limited
Warranty Coverage.

The new tank is part number 5R3Z-9002-AA and the dealer basic part number is 9002. Condition Code 42.

Seeing as how you have had so little help at the dealership so far, you might enjoy this trip to them quoting the TSB number (assuming your build date was prior to 4/26/2005) and letting them enjoy working on your car at no charge!

If that doesn't solve the issue satisfactorily, then revert to plan B above.

Hope that makes for a much better pony back in your stable!

Good Luck,

Difficult Fuel Fill/Nozzle Shuts OFF
by: John

Fuel System - Difficult Fuel Fill/Nozzle Shuts OFF
My 2006 GT is stored for winters.
This year when I went to fill the gas tank the fill nozzle at the pump kept shutting off. I could only get about 1/2 L of gas at a time. It took me 20 minutes to get 10 L.

I read all the above posted comments.

My "fix" was to drop the charcoal canister unit off the back and remove a closed solenoid valve that was preventing the air venting from going through the canister. With the solenoid restriction removed, the gas tank can now vent during a refill.

When I get around to it, I may replace the solenoid valve.

John in Hamilton, Ontario, Canada, 2006 GT

Hey John!

These issues all lead to the same place. Glad your fix did the trick.

Have a look at my post to Kitt90 and his pi**ed off pony. If you continue to have issues, check out the Technical service bulletin information and your Mustang's build date.

You may run into issues with emissions testing if you have it in your area. You could be told that your gas cap is defective as their test says that the cap won't hold pressure.

If I am remembering right, Ontario uses certified private shops to do the testing, so it may not be an issue.
Envirotest as did BC, have no wiggle room to tell a tester that it had to be removed due to fuel fill problems and they can work around it.


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