Hi All, I've searched everywhere and I can't find the info I need. We have a 2004 Ford Freestar (3.9) and whenever we try to fill up the tank with gas the pump keeps shutting off, or the gas comes spitting out. I have read that this is a pretty common problem and that it is usually related to the EVAP canister. I also remember seeing a write-up somewhere (with pictures) where a Freestar owner, who had the same problem, gave a detailed description of what to check, and/clean. If I remember correctly it was usually something pretty simple to fix. Unfortunately I cannot find that write up now when I need it.Does anyone have a link to share or advice to giver to help me get this thing fixed. Don't have the money to take it to a mechanic, much less a Ford 'stealer-ship'.

 

Here, this may help you out...

2004 Ford Freestar: 4.2l..The auto nozzles at the pumps always kick

 

I had that happen with my '06 Ford Escape. It was during the winter and the line from the fill port to the tank was freezing up. Ended up replacing the line and it was resolved.

 

I had a similar problem with my 2005 Ford Freestar. When filling the gas tank the pump would kick off many times and sometimes gas would splash back out. I did some research and found this to be a common problem with Fords as well as other makers and everything pointed to the charcoal EVAP canister that vents the gas tank to an outlet/solenoid vent valve just above the filler tube. I checked all the lines to make sure that there were no blockages and took off the canister. When I blew through the canister, air would pass through but it seemed restricted so I plugged one end and used compressed air to pressurize the canister and then let the air blow back out. I did this a number of times on each end and then tried to blow air through it again and the air moved a lot more freely. I only used about 10 to 15 psi for reference and this was enough. Any more might not be safe as the canister is built to handle vacuum not pressure.

I put it back on the van and it fixed the problem and I haven't had any issues with filling the tank since. It's been almost a year now and it is still working fine. One of the articles I read recommended that you shouldn't try to top off your tank when full after the gas pump kicks off once as this may force some liquid gas into the vent lines and into the canister which ends up plugging the charcoal canister with liquid, not just air/vapour that is exiting the tank as it is filled with gas. Taking off the canister wasn't too difficult but you can access the hoses/ends of the canister without taking it off if you jack up the car & use jack stands/use ramps and crawl underneath. However, just be careful as there isn't a lot of room underneath and always wear safety glasses when dealing with compressed air.
I hope that this helps as once fixed, no more stress at the pumps, except with gas prices!