I had a car that did the same type of thing to the fuel tank. It was a brand new car, but would cavitate the fuel tank and leave me stranded, because I thought I still had 1/4 tank of fuel. This happened a couple of times in which the dealer would install a new tank (under warranty) and send me on my way. A month later I was back in the dealership for another one. Finally, one of their technicians got smart. He pulled all of the fuel and return lines off at both ends and blew compressed air through them. When he did this with one of the return lines, "something" shot across the shop bay and hit the wall on the other side. They never did figure out exactly what it was, but knew that the return had been clogged and therefore the fuel pump was simply sucking up fuel without a means to relieve the vacuum and eventually it would cavitate the tank.
Long story, but check your return line for a clog.
Allan