2006 Ford Explorer Fueling Problem

Hello danvasey

As the gas level in the tank rises, the distance between the dispenser nozzle and the fuel grows smaller. A small pipe called a venturi runs alongside the gas nozzle. When the end of the venturi pipe becomes submerged in the rising gas, it chokes off the air pressure that holds the nozzle handle open and shuts down the flow of gas.
That is how it works and now back to your questions.
The problem could be the small pipe (venturi).
tank must be removed, fuel fill tube and hose removed to locate the pipe, may need to be replaced or adjusted