iamweasel

akirby is right. The ecoboost (or any other turbo motor) is VERY sensitive to how you drive. There is a much wider variation in fuel mileage in soft driving vs hard driving. If you have any sort of a lead foot and are making the turbo kick-in a lot then your MPG's will go down quite a bit. I have a Titanium FWD and my window sticker ratings are 22 city / 33 hwy or something like that. I average about 25MPG's in normal driving but I do 80% city driving. (My 18-mile commute doesn't have much stop and go and I generally move around 45-50mph but do go thru about 12 stop signs or stoplights along the way. So for one tank I decided to drive it hard and really have some fun. I was getting close to 21MPG driving like that. FWIW, I have taken the car on a couple road trips (a lot of highway) and was getting 31-31.5MPG. I thought that was about right given I probably averaged close to 70MPH. In addition, I have the optional 19-inch dark stainless H-spoke aluminum wheels which hurt the MPG's compared to the standard 18-inch wheels. So for me, this car is getting the MPG's I think it should. No complaints here....

Someone in an earlier post asked if anyone had truly used 16-ish gallons on one tank before. Well today I present the proof. Check out the attached pics, as you'll see I used 16.01 gallons on one tank (as shown in the car's gauge) and pumped in 16.20 gallons at the pump. I ran the car 33 miles past the time it said zero miles to empty. The pump initially stopped at 14.43 gallons but then a handful of clicks later (while pumping VERY slow) I stopped at 16.20 gallons.

Well today I confirmed with my own eyes my tank is over 16 gallons in capacity. I ran my car 37 miles past the point where it said zero miles to empty. I stopped at a gas station and I got 16.33 gallons in. I had a really slow pump so I think that helped some as I stopped the pump the first time at 15.25 gallons. I think it may have stopped sooner if I had a faster pump. (It didn't actually click-off by itself, though. The pump must be broken as fuel started coming out so I had to stop it myself. I had a little bit of lost fuel but not too much. It didn't make a big pool on the ground or anything as I just had to wipe a little bit off the outside of the car.) After hitting 15.25 I waited a minute or so and about 5 clicks later I was at 16.33. That is definitely the most I have ever pumped in at one time. So the moral of the story is yes, our gauges are too aggressive in calculating miles to empty and do NOT go more than 40 miles past the zero miles to empty mark. I clearly didn't have much fuel left at 37 miles past and another poster said they ran out around 44 miles past. I don't think I will push it further....

Talked to a Ford rep today. (Not the engineer I was trying to get a hold of but someone else who knows what is going on.) Basically, they said the TSB on the Escape regarding the gauge calculation is a "similar" problem to what is happening on the Fusion. They are working on the fix but they didn't have an ETA at this time. They did say that when the car hits zero miles to empty 1 gallon of fuel should be left not 3-ish as most of us have been seeing. So I am just going to check again with them in a few months to see if the fix has been released. (Or if I hear anything before then I will post it here. They have my # and are supposed to call me when the fix is developed.)

Sounds to me you may have a bad tank, too. On my car I could only get about 10.5 to 11 gallons in when at zero miles to empty, but after changing my tank I can now get 13.5 gallons or so at that same point. Better for sure but still not where it needs to be in my opinion.

Nice find! I think this is exactly the problem we are having with our Fusions. I am going to print this and take it Friday when I drop off my car and see what happens. At minimum, it will make the dealer open a warranty ticket on the problem which will alert Ford. I filled up my car yesterday after running it 20 miles past the point where it said zero miles to empty. The fuel gauge went yellow around 17 miles to empty and then turned red at 5-10 miles to empty. The pump clicked-off for the first time at 13.61 gallons and I stopped 3 clicks later at 14.39 gallons. Pretty sure I still had a couple gallons in there when I stopped.

For those with fuel tank filling issues read this thread: http://www.fordfusionforum.com/topic/8957-2013-fusion-fuel-tank-filling-issues/ It's 9 pages now but post #37 is the one that sums up most of the issues.

I think the variability is caused by different nozzles. The new filler neck design is more sensitive to "out of round" nozzles where fuel is sprayed in a wider pattern. The newer nozzles should be better than older ones as far as that is concerned but there is no real "fix" for that problem right now.

Thanks for the update. I have called the engineer twice in the past 2 weeks and I've yet to hear back from him. That is odd since he was very responsive when I had my initial fuel tank issues a couple months ago. I am taking it to the dealer on Friday for a 5,000 mile service and a couple other minor things. I am going to tell them about my 13.x usable range, too, so maybe if these dealers keep reporting it something will be done. I am pretty sure this is an issue with how the gauge calculates per my prior post (Re: the canadian law thing) and not an issue with the tank itself anymore. (With my new tank that is, my old tank was much worse as it only had a 10.x usable range.) I have some other Ford folks that I spoke with about this, too, and will reach out to them to get more info since I'm not having any luck getting a hold of the engineer now.

Yep...all of this after the replacement tank. With my old tank I was only able to get 10.5 to 11 gallons in the tank at zero miles to empty, and now I can get close to 14 gallons in. So it is better now, but still not where it should be in my opinion. This is because they had to change the way the gauge calculates due to some new Canadian law. (I mentioned this in one of my earlier posts.)

My gauge turns yellow when it gets about 10-15 miles to empty. It then turns red about 5-10 miles past the point when it says zero miles to empty. At zero miles to empty, I can only get about 13.5 gallons in there until the first click. After a bunch of clicks I can get about 14.0 to 14.25 gallons in there. With a 16.5 gallon tank I would expect it to take 15.0 to 15.5 gallons in my opinion. (In every other car I've had the reserve was usually about 1.5 gallons, not 2.5 like this car.)

That was me. I left a message for the engineer so I am waiting for him to call me back. I wanted to follow-up with him, anyway, to see if they have found a resolution to reprogram my fuel gauge so it doesn't go red with 2.5 gallons left in the tank. I don't think it would be appropriate to post his cell number on a public forum so I will ask his permission first. I'll let you guys know what he says.

My car can definitely accept almost 16.5 gallons of fuel. When the dealer replaced my tank they put 1 gallon in the car while in the shop bay, then drove it to the gas station and they were able to put 15.3 more gallons in there at the pump. (So that adds up to 16.3 gallons total.) I saw their receipt from the fuel station but I don't know how many clicks it took to get that fuel in, but they said it only clicked-off a few times. So today I filled up after going 11 miles past the point where my gauge said zero miles to empty. My fuel gauge was RED at that point. (It went from yellow to red about 5 miles past the zero miles to empty point.) It put in 13.51 gallons until it clicked-off the first time, and then I jammed some more in there and stopped at 14.70 gallons after going through about 10 click-offs. So it seems to me there is a 2 gallon reserve on the car. More than I think it should be but that is how it is.....

Did you happen to discuss the issue with the Miles to Empty calculation, too? (Why even at 0 miles to empty you still have 2.5 gallons of reserve in there. That is too much in my opinion.)

For those of you who's dealers say they have checked the tank and it seems ok I don't think this is possible for them to determine that. The internals of the tank are the problem with some of them and the only way that you can see it is to x-ray the tank. That is what the Ford Engineer did with mine. The dealer was not able to find the problem themselves and replaced the tank at the direction of the Ford engineer.