Fuel tank overflow

[Malibu46pt]

Filled my fuel tank “FULL” for the first time. The tank overflowed. Filled the tank until the fuel nozzle shut off, just like you do on your normal car. Is this normal? Is there a procedure for filling the tank less than full? Did I do something wrong?
HELP!

[egchewy79]

what do you mean overflowed? like out the top of the filler tube?
or are you seeing fuel dripping from underneath?
if the latter, did you swap out the filler neck grommet to an OE one from Ford? the FFR ones are know to tear/leak when tank is full or if taking a corner, allowing fuel to slosh to the PS.
it could also be coming from the fuel pick up or sender O rings if they are damaged.

edit: if you mean fuel coming out of the filler neck, what I do is usually listen for the tank to get full and slow down the fill rate once the pitch of the fuel changes. I rarely will leave it in, w/ the lever pegged, and walk away b/c I don't trust the triggering mechanism to stop the flow, at least on these cars.

[phileas_fogg]

Did you follow the F5 video instructions & put fuel safe gasket sealant on the o-rings between the fuel pump hanger/tank and fuel sending unit/tank? If so, that's very likely the problem. The sealant gets hard, cracks, and leaks.

To fix leaks at those o-rings, simply replace them & use a dab of motor oil to lubricate them at installation. Oil is the Ford-recommended lubricant on these o-rings, and it keeps the steel retaining ring from tearing the rubber.


John

[Nigel Allen]

X2 on what John said. I had fuel leaking from the fuel level sender. Took the square profile gasket to a seal specialist supplier. They supplied me with a slightly larger thickness O ring suitable for fuel application. Like John, I installed it with a little lube. 5 years later, leak free.
I also purchased an OEM filler neck gasket, but haven't fitted yet, as the FFR gasket is still sealing ok. I often fill my tank quite full and it might stay that way for a couple of weeks at a time. Have had no further issues.

Cheers,

Nige

[Malibu46pt]

O ring on fuel level sender was the source of the leak. O ring appears to be too large. Looking for a replacement . Should solve the problem

[Theshandman]

I often fill my tank quite full and it might stay that way for a couple of weeks at a time.

LOL. Yer not driving your car often enough, Nigel!

[Malibu46pt]

How many gallons of fuel does the tank hold?

[FLPBFoot]

How many gallons of fuel does the tank hold?

15.4 gallons