could possibly be the pump you are using too, it could be pumping too much too fast although I highly doubt that but sometimes I've been to pumps that pump extremely fast and cause exactly what you said. There is a TSB as previously mentioned that concerns the filler neck not being able to accomodate quick fillups. Oh and the twisting the handle 90 degrees always works for me when I run into this problem. As for the gauge being flakey.... From many experiences w/ other ford vehicles, expecially my ex-boss's expedition, if you continually overfill the tank by trying to cram more gas in after the pump shuts off, overtime, repeatedly doing this causes the float valve to mess up and start to be inaccurate. I've seen 3 vehicles go in for a new float assembly from doing this.
