My Step Mom has a 1995 960. And after she fills the tank with gas and drives the engine quits and wont restart after using just around 5 gallons or so of that full tank. But if you add the missing fuel it starts right up and runs great. Also her gas gauge is not working correctly. I know that its 5 gallons because thats how much we can add before the tank overflows. Does anyone have any ideas?

The others are right on track with this, but the down part of the pump/fuel gauge stalk is metal. But it has an angle curve to it, so it sounds as though someone worked on this and did not get it correctly back into position.

Reinstalling the stalk is very tricky, getting it back in at the correct orientation is the tough part. With it correctly positioned the pick up end sits in a bowl that is molded in the bottom of the fuel tank, if it is not correctly seated then because of the curve in the stalk it will be drawing fuel from a higher area in the tank, so what is happening is the pick up tube is not at the bottom of the tank but is incorrectly located about 3/4's of the way up the tank.

This will not be good for the fuel pumps, as they get cooled by the flow of fuel and with out that fuel will overheat and shorten their life span, so this needs to be correct asap. Also it is not a good idea to run around with a gas can in the car trunk if that is currently being done.

Let us know how this shakes out. If the car was serviced for a fuel problem in the past then it should go back to them for the correction.


DanR '94 964 355,000 miles (121,000 on the new engine)
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DanR

As preveiously mentioned. More then likely a split in the In-tank Hose that connects the Pump to the sender. Very common in the 200's The rubber hose sits at about the 1/2 tank mark. Burn 5 gallons and the hose starts to suck air.
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'75 Jeep CJ5 345Hp ChevyPwrd, two motorcycles, '85 Pickup: The '89 Volvo is the newest vehicle I own. it wasn't Volvos safety , it was Longevity that sold me http://home.lyse.net/brox/TonyPage4.html

Pull the fuel pump and you'll likely see the problem. Could be the submersible hose the connects the pump to the "sock" on the bottom of the assembly. The hose may also be inhibiting your float from working.