Dale,
With the very first batch of 2004 Prius, there was an issue with the tank that caused capacity to shrink and the gauge to be inaccurate. However, that issue was fixed long ago and I haven't heard of this problem happening -- especially with the latest vehicles. You need to have yours checked out. Keep in mind that spilling a cup or so of gas really undoes the benefits of owning a green car.
As a side note, welcome and congratulations! You're our 1,000th member. I've posted an announcement in the appropriate section and emailed you a few minutes ago.
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