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Originally Posted by wshepherd
I have a 2004 Prius, I bought it in Aug '04 and I have just under 20,000 miles. I had it in for the recall a few months ago and haven't had any other problems.
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I'm inclined to believe that your experience is probably one-off. I'd see if another tank does the same thing.
If you gas up at the same place notice how each pump operates. If a pump filler valve is old or messed up in any way that can have a pretty significant effect on how well it fills up the Prius tank. Some pumps are very sensitive to back pressure, which most conventional tanks might not have much or. However I firmly believe that the bladder has a great deal more back pressure than a conventional tank and as such a sensitive pump will make filling difficult.