Ok, so I filled up yesterday from an almost empty tank. I know the tank is full because I put a little over 16 gallons in. My gauge would not go up to show that it was full. I turned the truck off, and started it back up, and nothing. I checked again this morning, and still nothing.
So, I checked the gas cap... it was on, not too tight, 2 clicks to be exact, took it off, tried it again. Nothing. So I looked at the gas cap again... the little metal tab that is at the top of the filler tube is gone! It's the thing that gets pushed in when you insert the pump nozzle, spring loaded I think. Could this be down in my gas tank? and it not being there cause my gas gauge not to show that it's full? Has this happened to anybody else? If so, how much am I look at in work and/or cost to get this problem fixed? My gas cap light is not on, if my truck even has one. Btw, it's an 04 Edge 4x4 4.0L SOHC. Please help, thanks guys.

 

Also, I'm kind of hoping and thinking there has got to be some kind of filter to keep debris out of the gas tank, so maybe all I'll have to do is take the filler tube off and fish out the circle tab thing. Not even sure how to do that, any suggestions and help are appreciated.

 

That little flap may have gotten caught on your float/level sensor if it can make it way through the small filler hose. It doesn't seem like that would happen but I have seen stranger things happen. I have never seen a filter to keep debris out of the tank.

If you want to take a look in the tank to see where the little flap went, it is easier to pull the bed than drop the tank. You might try going over some bumps to see if you can knock the little flap off of the float/level sensor. It may not be the problem but it is worth a try.

 

I work at an auto transport company, and if the cars are being delivered to the docks they have to be below 1/4 tank in fuel. If we cant get the fittings on, or dont have the right fittings we push a stiff nylon hose down the fill tube with an edge on it just to go through that filter. Trust me, 95% of cars have one these days.

Pull off the filler and see what you can see. I think the fuel pump on these are located on the top of the tank. Pull it out and see if the float is stuck.

 

Haven't had a good chance to look at the actual filler hose yet. Do I have to drop the tank to get it off, or is it something like hose clamps that will come off easily? Guess I could check out my Haynes manual. Hopefully it will be something easy. Not looking forward to spending money on senseless crap like this. Best to save it for mods, lol.

 

Ok, so I talked to the parts department at a Ford dealership in the area. They told me that at the bottom of the fuel filler neck, there should be a "thing that looks like a cross", called an anti-siphoning device. This should prevent my little tab from entering the gas tank. So, I took a look under the truck.
The filler neck is connected by 3 screws to the side of the bed, inside the fuel door. It goes down about 10 inches or so, curves to sort of flatten out and connects to a rubber hose with hose clamps. There is a smaller line right next to it that seems to do the same thing, not sure what it's purpose is tho.
Those rubber hoses go over the frame rail, and into the top of the gas tank. So, I'm thinking, I can disconnect the rubber hoses from the filler neck, disconnect the filler neck from the truck by removing the 3 screws, flip it over and shake it, and the piece should fall out. I will have to wait until this weekend to try this, but I will take pictures for future reference, in case this ever happens to another Ranger driver.
Btw, Ford would have to order a new filler neck from national catalog, 3-5 day shipping, for $215... wtf!
I say taking the original off and trying to fix it, and/or going to a junk yard is a much better option.
They also said that my gas gauge not going up has nothing to do with this problem, but the sensor, which I suppose sounds right, but my issue can't be helping the situation any.
Thoughts?

 

Pull the bed. Take the a look at the pump assembly. Make sure the float moves freely.

If the gauge is still in-op you have a wiring or sender issue.

 

That sounds like a terrible weekend's worth of fun. And hardly possible. I live on a military base, don't have a garage, or any help for that matter. But, if I did decide to try and remove the bed all by myself, after removing the drop in liner, what would it involve to remove the bed? How heavy is it? Could 2 or 3 people do it?

 

Pull the drop in liner out, remove the 6 bed bolts, unplug the taillight wiring harness just above the bumper. The bed shouldnt be that heavy it just cumbersome. And yes 2 or 3 people can lift the bed.

 

Bed bolts have any kind of thread lock? Recommend that I use thread lock to re-install ? Possibility of doing a body lift in the future, so don't want it to be too tought to get off again later. Too bad I don't have the money to do the lift now, lol.

 

Being an 04 it should come off easily. You will need a 1/2 breaker bar a good t-55 torx bit. A hammer and block of wood to get the ring off the tank.

pull the tailgate
6 bolts hold the bed down
3 bolts on the filler neck
one harness for tail lights just under the rear of the bed

I have pulled my bed and reinstalled in a an hour with friends. I have had it off a few times now.

 

Guess I'll give it a shot. Have custom wiring ran from 3rd brake light to run 3 bulb set-up in tail lights tho, so I'll have to figure something out, it's more than just disconnecting a harness. Thanks for the help tho, looks like I have some work ahead of me.