There's a thread that Andy made about the issue.. He's got a 1st Gen and the fix required cleaning up fuel components in the tank.. Easy fix and straight forward, but I suggest you take it to the dealer for warranty work.
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TapaTalkin'
When did you start having this problem the first time?
Could of sworn I saw a TSB on this fuel issue.
---------- Post added at 09:10 PM ---------- Previous post was at 08:56 PM ----------
Here found it for you:
Summary of ITB08041:
IF YOU CONFIRM The fuel tank is difficult to fill more than ½ (filling nozzle continues to click OFF when the fuel tank is more than ½ full), ACTIONS Install the Cut Bracket (cover) onto the Fill Limit Vent Valve (FLVV) inside the fuel tank. See this bulletin for further detail.
Or this:
ITB05031
IF YOU CONFIRM The fuel tank is intermittently difficult to fill. ACTION Replace the shutter valve inside of the fuel tank. See this bulletin for further detail.
The transmission costs even more, but so what? Why are you concerned about the transfercase; giving you problems?
TapaTalkin'
Something wrong with your transfer case?
How much is an extended warranty?
My transfercase is making the same sound it was before they fixed it ..sounds like two metals rubing against each other....last time I asked the dealer about the warranty they told me $1900
Sent from my HTC Sensation 4G 2
I remember there is a TSB for the transfer case too. This time tell that dealer to follow the TSB procedures instead of guessing how to fix it. It should of been done right in the first place smh:
Vibration From Transfer Case
Summary of ITB09064:
IF YOU CONFIRM: A whine noise and/or vibration from the transfer case assembly when making right or left turns at slow speeds, and/or stopped with steering wheel turned to almost full extent in either direction, and then applying slight acceleration.ACTION 1. Replace the electric controlled coupling in the transfer assembly. 2. For FX35 only, built before the following VIN and date, also replace the air breather vent. - FX35 built before JN8AS1MW(*)AM 851594 and October 27, 2009. See this bulletin for further detail.

damn i wont let them touch my transfer case. it just never drives the same after.
remember, you have two tanks in the FX... maybe one just isn't opening up properly. if you need an extended warranty ill hook it up
Does yours have the transfer case problem too?
So this is the fourth time I filled up my fx and the fuel gauge nidel won't go all the way up to the F marker ...was wondering if anybody had this problem or know what's causing it ...? Thanks for your time
Sent from my HTC Sensation 4G 2
YUP......just at the dealer on Saturday with the same problem. The fuel tank sensors were out of whack and they are ordering new ones to be installed when they arrive.