302 Hi Pro
Boss 302 - Racing Legend to Modern Muscle Car
I suspect it is a vent issue. Check the vent hoses first.
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I know this is an OLD thread but is there a fix to this? I tried to fill up my '07 for the first time today and it would only take 7 gallons.
I tried again today and just held the nozzle so it barely trickled in and I was able to fill it up.
The filler neck is being replaced this week and I'm hoping this will solve the problem.
FWIW I had this discussion with the guys at Kohr about my 07 Gt500. Dean said that I must have an early 07 since they figured out the problem, changed the frame rail and redesigned the fuel intake around January 07.
Soo.. his recommendation was to just turn the fuel nozzle upside down and the issue would be much less, or possibly find an 08 fuel inlet and cut the end off, and replace the 07 inlet with it.. that might help the issue, providing all the vent lines and whatever are not flat.
Other than that, I'm not sure what to say, or how the Boss mustangs are affected.
Had issues filling up my boss back in 2016 after a two day thill weekend where temps were in the high 90s, low 100s. Took almost 20m to fill up before heading home. Turns out the plastic evap (?) line that runs next to the exhaust where it goes over the rear axle, had melted. After having it replaced at the dealership, I wrapped it in tons of extra heat shielding to try to keep insulated from the exhaust heat. Haven't had issues since, but I also haven't done a ton of trackdays in the last few years, and definitely haven't done any super hot days like the one that caused this.
Really sucks, since being in California, no indy shops are willing to touch this system for fear of the EPA coming down on them. Seems to me that the best permanent fix for this (besides deleting...) would be to replace those plastic hoses with something that won't melt.
Attached a shot of the melted line.
View attachment 58289
Literally melted the same exact line and mine wouldn't fill either. I'd recommend cutting this out and replacing just that section with line as the whole assembly isn't exactly the cheapest piece.