I just finished a 2,784 mile roundtrip, and the subtank and main tank had no problems filling up all the way at every gas station, regardless of how full or empty the gas tank was. I had been having this success for several weeks now, but didn't want to (finally) claim full victory until after I had tested it on this trip.
In my case, the final modification that fixed this the rest of the way is related to the main tank's fuel pump. When I had originally purchased all the parts to install the factory subtank, there were two fuel pumps to choose from that had the subtank siphon mechanism. The options were:
- The pump that @grinchy had used (that is a drop-in replacement with a functioning port for the siphon tube), which was out of stock, or
- A pump (also drop-in with the siphon port) that also included an extra vapor vent port that is used in some parts of the world that have different fuel vapor regulations, and this pump was in stock.
So naturally I had chosen option 2 since it was the only one in stock. Here's a photo of what the top of that pump looks like, with me pointing to the extra vapor vent that would be unused in my installation (and thus why I had capped it off in this photo).
Well, several weeks ago that allegedly fuel-rate rubber cap had deteriorated to the point that it cracked open and allows fuel to spray out (after only 2 years of use).
At that point I decided to remove the rubber cap and replace it with fuel hose that would vent back to one of the unused vent ports on the subtank. Before this happened, I had started to suspect that air gets trapped in various places in the main tank during fill-up, and that could cause sudden burps of air or uneven backpressure that causes it to click off prematurely when filling up.
Even before installing the subtank a few years ago, I would occasionally visit a gas station that for some reason would not be able to fill up my tank without clicking off constantly. Then, of course, after installing the subtank, it had become impossible for the main tank to fill up completely when it was starting out empty. Adding this hose from the pump's extra vent port to the subtank's extra vent port appears to have completely solved this problem. I suspect that air likely get trapped somewhere behind the various baffles the main tank has inside it.