Contour Enthusiasts Group Archives Forums General Troubleshooting Fuel Filling problem

I have a 98 Contour SVT which I recently purchased used, in good general condition with numerous minor problems. The most annoying one turns out to be the trouble I have filling the tank.

The gas pump will fill about half a gallon, and then automatically shut off. I have to wait about 10 seconds, and then pump another half gallon. Sometimes I get a whole gallon. Whoo-hoo. It takes about 10 minutes to fill the 15 gallon tank that way.

This has happened three times. The first time it happened, I thought the fuel gauge was busted, because the tank was "full" so quickly.

I live in San Diego, CA but I bought the Contour from Montgomery, AL. Perhaps the type of gasoline pumps differ from here to there. Theirs could be lower-flow, or ours could be finicky.

Has anyone else experienced this problem? Ideas?

There was a TSB on this very subject - I remember getting the letter, but my SVT never had this problem. Has to do with replacing a flapper valve in the fuel filler pipe, IIRC.

Look here .

On the web page you get to from this link, look for #69 on this list, TSB 98-15-3.

Good luck.

Yes, this was a problem on very early contours,
my 1995 had this problem and it was a TSB or
minor recall on the subject....they have to
replace minor part..

Is this related and is it going to be a recall that they pay for?

01M04 JUN 01 Campaign - Fuel Pipe Flapper Valve Additional Coverage

Stephen

I believe that anything termed as a "recall" is paid for out of Ford's pocket - no deductible, no out-of-pocket, no nothin'.

A TSB repair is performed only if the customer complains about a specific problem and that specific problem is covered in a published TSB.

I'm not 100% sure what this means. If I had to hazard a guess, I would say that an owner with a higher-mileage car can still get the original TSB problem corrected at no cost, whereas normally a higher-mileage car with the fuel fill problem would not be covered under the original TSB.

When I got my SVT they had to replace the fuel pump to get the car certified. At the same time they replaced the Fuel Filler Pipe. I assume they used the redesigned flapper valve. The first time I gassed up last week I had the same problem. This week I gassed up but only put the nozzle 4/5 of the way in and no problem. I am curious why I had the problem the first time. Could it be from it being the first time it was used?

I had this problem numerous times until Ford fixed it at their expense. It is definitely the flapper valve at the bottom of the filler pipe, made of the wrong material that degrades with time. They also said they replaced the filler pipe, but I don't believe it. It even stuck once after they fixed it, but never since then.

I filled up again tonight without any problems. Lets hope it was just a one time thing.

I've read that the exhaust and fuel tank have to be removed to replace this $9 fuel flapper valve and Ford apparently charges $300-$400 for the repair. Is it really all that hard for us weekend mechanics to do? I would think that with a nearly empty tank it wouldn't be all that heavy and I've replaced my entire exhaust system, struts, springs, etc., on my own. Any special tools involved in doing this? I don't mind laying on my back for a few hours if it saves me $400.

It takes me 7 minutes or more to fill my 98 Mystique tank verrrry slowly and it's getting irritating.

Jeff

This is a small nuisance problem for me on my '98 and Ford dealer should be contacted as slow filling/premature pump shutoff is a "recall" item. They use another term (sorry, can't quickly find their notice), since recall is for safety items, but will replace at no cost. Problem I believe is size of air-escape hole, in flapper valve assembly.

My '97 has a larger hole, does not have the problem and is not subject to this "recall".