After not being able to fill up at the big boy pumps a couple times I decided I needed to fix the tiny fuel filler neck. I was towing both times and really needed to use the big rig pumps, the second time I had my 33 foot tt behind me and clogged the gas station just a bit. Anyway...

I read about a simple mod to 'open' up the fuel filler neck to allow the use of the big rig hi flow nozzles. My 2000 has a reduced inner hole with a spring loaded trap door. This piece is made of some sort of nylon and is pressed inside the fill neck. To keep plastic shards from falling in the gas tank, I removed the fill neck from the tank. It took a little work after loosening two hose clamps from the fill hose and vent hose. Once the clamps were loose, I had to twist the filler tube about 180 degrees counter clockwise to get enough room to get it from under the fender. It's kind of a PITA but not too bad.

Once the tube was out I used a Dremel with a roto type drill bit and cut the guts out. I then used a small sanding drum to smooth it out. Re-installation of the hoses was alot easier than removal, just had to start 180 degrees out then twist it in. Oh yeah, don't forget to blow out all the plastic shavings before you re-install the neck. All in all it took about an hour, not a bad mod, especially for the added convenience on the road. Glad I finally did it.

Before.


After.

 

That was one of the dumbest things Ford did (before the 6.0 ) Glad they fixed it in later years.

Congrats on the mod. I'm sure you'll enjoy the fill rate of the big pumps.

 

I need to look at mine again, I've never not been able to fit a pump in it though and mine is a 2000.