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.