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Just thinking out loud but a few things that would/might be different when the tanks full:
o fuel return, but not sure how this could cause an issue, maybe the fip or lift pump has issues when it can't return? Doesn't sound likely to me though
o Air vent in the tank, again not convinced, but I believe that the discos have a vent hose leading up to the filler to allow air into the tank as the level drops (I've seen a video, but it wasn't clear what year or petrol or diesel) maybe that isn't allowing pressure relief once full. Can't think why it would be any better after that though.
o Suspension, maybe it isn't running rough and you have some bush or similar issues at the rear that show up with the full 80 - 100kg of fuel back there. There is a strip of road here in Adelaide that my Jimny feels like the engine is conking out as you drive on it, freaked me out every time until I realised what it was.
o In tank pump electrics, this occurred to me as I was writing and seems feasible. There are electrics running to to the pump inside the tank. When immersed in diesel perhaps they are not making good contact or similar, just an age vibration thing.
This last one sounds like a possible to me. I haven't replaced one of these, so I don't know what the wiring is like and how they are sealed or could suffer.
Originally Posted by workingonit
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