My 2001 edge needed a new gas tank(someone drilled a hole in it,wasn't me)Checked into it and 01,02,03 tanks are the same.Found an 02 at the parts yard put it in when I went to install the sending unit the seal was just slightly to big after measuring the out side of the threads on the tank they were 3/32 smaller. I talked to the ford parts man and he said the98,99,00,01,02,03 all use the same threaded locking ring. the ring fits my old tank very tight and is loose on the new (2002) tank. I put it on and it tightened up ok< but this seems very odd to me anyone else seen this? I do not have the ring that came on the 2002 tank

 

I think there was a production change at some point. My skid plate came off an 03, and did not fit right on my 02. The tanks were clearly different and I had to modify it.

 

they did a lot of tweaking between 01-04 there were tons of new emissions and safety regulations that went into effect so they are the same generation but its kinda a crap shoot as to what will fit. Also was the donor a flex fuel? they had different sending units to accommodate ethanol could be the source of your problem.

 

I believe what happened was the tank was off the truck sitting in the bed.I am thinking that that black plastic tank sitting in the sun all day long for who knows how long? I think that the tank shrunk a little. I have it on the truck and it seems to be ok. The locking ring was just a little loose that why it believe it shrunk.

 

The gas tank itself should not be different at least from 01-03

 

I really do believe it shrunk theirs no other explanation

 

I don't believe the tank sitting in the sun would cause any sizing changes.

I do know tank sizes changed between regular cab short bed, regular cab long bed, and extended cab short bed. Could it be possible you have a new tank from a shorter wheelbase truck than yours?

I haven't had to mess with my Ranger's fuel pump (yet) but do know Ford can be pretty nutty with fuel pump changes..... 1998 Lincoln Continental had 3 different pumps. Two are readily available from parts houses.....and the third is a Ford only thing. Guess which one my parent's car had? YEP.

In regard to skid plates.... Ford changed fuel tank skids about midway in the 03 model year. Started with one that bolts to the frame and crossmember to one that bolts to the tank straps. I too bought the strap mounted one from a 05 before finally finding a frame mounted one off a 99.

 

The tank is exactly the same as mine except the treaded part where the lock ring goes is 3/32 smaller. After talking to the ford parts girl the 98 through 03 take the same lock ring.