Gas pump shuts off after pumping about .5 gal. when the tank is not full

Did you try filling at a different service station. Your issue seems pretty rare, but other have reported it.

https://www.google.com/search?q=ford+taurus+2002+won%27t+fill+gas

..

Fuel pump dead or dying. Injection systems need 110 psi, and a pump only doing 30psi will still not run .

You have a crack in one of the flexible fuel lines inside of your gas tank that lets the pump suck air when ever the gal level is below the level of the crack in the line. It is an easy repair once you remove the fuel pump. Should cost you about 3 dollars if you do the work yourself. To test fill you tank all the way to the top and go turn a corner and see what happens. I bet it will run just fine with a full tank.

There is a fault with the fuel tanks in the 06 cars (and some 05). It is a well known problem and Ford has issued a service bulletin on the issue.

It also seems to be a problem with the fuel pumps at certain gas stations but not others. Try a couple of different service stations (not the same fuel brand) and see if you have the same shut off problem because some people have found that the pumps at some gas stations do not cause premature shut off when re-fueling their 06 Stangs.

I would contact the nearest Ford dealer service people and see if they will rectify the problem for you FOC even though the vehicle is now out of warranty. In some vehicles the fuel tanks were replaced to fix the problem but not in all apparently.

In the meantime you can try 2 means to resolve the problem that has worked for some (not at the same time).

1. Turn the fuel pump nozzle 45 - 90 degrees when re-fueling and do not run the pump full bore. Slow the fuel flow a little.

2. I would avoid this one and I do not recommend it but it has worked well for some people with your problem. Turn on the car's ignition (not the engine)before you fill the tank . Switch it off immediately you have completed re-fueling.

you must have a kink in the new filler tube. look to make sure gas can flow easily threw the filler tube

the vent tube that runs beside the filler hose is crimped shut or clogged

you are either lacking SPARK or FUEL. You put 5 gal in the tank, but is the FUEL PUMP working ? The lights and radio operating only indicate ther is power in the battery.. Hope this helps.

In tank, see link for procedure. Make sure it's pump causing problem, as other items come in to play also.

http://www.autozone.com/shopping/repairGuide.htm?pageId=0900c1528023b196

fuel pump could be overheating and need replaced, if this happens exactly the same each time it seems that is the case, the gasoline in the tank cools the pump through the returned system, alot of people that drive around near empty all the time will burn out their fuel tank quicker because of the pump not being cooled properly, you have spark when the car wont start?

take it to a GM dealer and see if the electronic key reader needs to be replaced