Loud clunk when filling fuel tank ⛽️

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Muddy Bean

Muddy Bean

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When my 2015 EL is almost full and the fuel nozzle is about to click off, my suspension makes a loud settling noise clunk. It does this every single time I fill up. And sure enough, without fail, as soon as I hear the suspension clunk, the nozzle clicks off. Is this typical?


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Patsfan4lif

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Muddy Bean said:
When my 2015 EL is almost full and the fuel nozzle is about to click off, my suspension makes a loud settling noise clunk. It does this every single time I fill up. And sure enough, without fail, as soon as I hear the suspension clunk, the nozzle clicks off. Is this typical?


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Probably just the float sensor in there hitting the top of the fuel level sensor
 
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99WhiteC5Coupe

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Muddy Bean said:
When my 2015 EL is almost full and the fuel nozzle is about to click off, my suspension makes a loud settling noise clunk. It does this every single time I fill up. And sure enough, without fail, as soon as I hear the suspension clunk, the nozzle clicks off. Is this typical?


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I would suspect you have something loose - and maybe the fuel tank mounting, or a defective fuel tank.

You should have the undercarriage, and the fuel tank and fill tube examined. Fuel weighs about 7 pounds per gallon, which could cause the fuel tank to sag or the wall of the tank to expand (if defective). The fuel tank is made of a composite - not metal.

I do NOT think it is “just the float sensor” hitting the top of the fuel level sensor (post #2).

I have a 2015 Expedition Limited 4x4 and the fuel tank and suspension NEVER makes a noise when filling - and I fill it up when I get gas.

Even if your warranty is expired, I would recommend having it inspected on a lift.
 
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Patsfan4lif

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99WhiteC5Coupe said:
I would suspect you have something loose - and maybe the fuel tank mounting, or a defective fuel tank.

You should have the undercarriage, and the fuel tank and fill tube examined. Fuel weighs about 7 pounds per gallon, which could cause the fuel tank to sag or the wall of the tank to expand (if defective). The fuel tank is made of a composite - not metal.

I do NOT think it is “just the float sensor” hitting the top of the fuel level sensor (post #2).

I have a 2015 Expedition Limited 4x4 and the fuel tank and suspension NEVER makes a noise when filling - and I fill it up when I get gas.

Even if your warranty is expired, I would recommend having it inspected on a lift.
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Oh sorry for posting about what the noise might be. Obviously you’re a f***ing expert since you know everything that the noise is NOT. Why don’t you tell him exactly what this then bc I do NOT think it’s the gas tank sagging
 
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Andrew Roth

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While I cannot be of much help, I will add that mine does the same thing. Not quite as regularly as yours but every couple of times when refueling I will notice this very loud clunk when the tank gets close to full. It is so loud that I look around to see if others noticed as well. I am curious to hear what others have to say.

For the record, mine is a 2017 EL
 
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Copper93

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There is a vent valve for the Evap system. It is possible the valve is popping shut. Do you have any problems filling the tank? Do you have excessive gurgling or bubbles when filling? Does it seem to happen all the time or just when filling the tank completely?
 
mossback

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Muddy, FWIW, I have never noticed this on my truck. Very curious to know what it is if you find out.
 
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Patsfan4lif said:
Oh sorry for posting about what the noise might be. Obviously you’re a f***ing expert since you know everything that the noise is NOT. Why don’t you tell him exactly what this then bc I do NOT think it’s the gas tank sagging
Click to expand...

My first guess was you posted this right after the Pats/Lions game Sunday.
 
1955moose

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My best guess is you've got rear air suspension, and something has gone awry back there. You or a shop need to rack it up, and check it all out carefully. Could be an air shock acting up, or something that broke loose. It could be the weight of the fuel is making the air ride pump up and top out a shock or mounting. Just a guess though.

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Muddy Bean

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Sorry, been on the road... the clunk is loud and definitely not a float sensor. It sounds as though the suspension is settling. I do not have air suspension. I have the nivomat struts. I might try to take a video/audio clip of it if I get a chance and post it. I’m wondering if it’s a tank mounting strap issue or a suspension issue.


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