There could be part of a gas can nozzle in your fill tube, or maybe a piece of hose that someone tried to use for siphoning. Ie: a blockage.

 

i notice on some gas station nozzles some have a hole near the tip and some don't. maybe that has an effect?

 

It's been a bit to rainy and cold to get at the filler tube. I have taken both discos to many different gas stations, one fills always, the other not so much. It is NOT the gas station, there is something wrong with the filling system.

I'll know more when I can get the filler tube out again and work on it.

 

 

Hey there, I still have the problem but have been busy with our other cars to fully solve it yet. I replaced the purge valve with a Hyundai unit, and am currently down to the last two culprits. There is a solenoid going to the charcoal canister I believe, and that could be the culprit, or some form of blockage in the filler neck assembly.

I'll start with the charcoal canister set up first, and then if that doesn't work I'll look to replace the filler neck.

If you solve the issue please come back in here and report, and I will do that same

 

Just to finish up my experience, in the end nothing fixed the problem.
Ii replaces the fillet neck with another used one and the same situation persisted.

I unplugged and and plugged in all of the vent hoses coming out of the filler neck and gas tank, but there was no change.

I am thoroughly stumped on the issue.

 

I have/had the same problem, the pressure is just too high for Discos fillers, just use the middle or slower of the two setting and wait a second or two longer.

 

I had this problem with my 04. Turns out if I fuel up in the morning I have zero issues but if it’s warm out in the pm I have the same issues as you.

 

i just started having this problem today. never had any trouble filling this truck but then today it would quickly fill to the point where it would shut off the nozzle unless i had it flowing really slowly.
the temperature thing is curious. very hot today so i'll try to remember to fill when it's cool next time. but it would be nice to find a fix for this.

 

You know, unfortunately I never solved this, though I didn’t trouble shoot the charcoal canister which could have been plugged up.

i ended up selling the disco for an 04 Disco that doesn’t have this issue..... yet.

good luck, but I would look at the canister and tubing.