2011 Ford Explorer: fuel leak

Filed Oct 7, 2020 · Fuel system · 169,132 miles · MI

As a repair shop owner, the vehicle owner stated that there was a strong fuel odor after filling the fuel tank. I noticed fuel stains from the top of the tank so I removed the tank and found fuel leaking from the fuel pump module. I found the steel lock ring retaining the module to the plastic fuel tank had rusted and the resulting rust 'bloom' had crushed the plastic flange causing the fuel leak. I have noticed this on another car ( 2007 dodge grand caravan, VIN [xxx]) just last week with the same issue. After sharing the pictures with a diagnostic discussion group, others have seen this around the country and canada, especially in the "rust belt" states. This issue seems to apply to any fuel system with a plastic fuel pump module and a steel lock ring in a rust prone area. Information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(b)(6).

Filed Dec 16, 2019 · Engine, Fuel system · 48,000 miles · AZ

Tl* the contact owns a 2011 ford explorer. While driving, the check engine warning indicator illuminated. The vehicle was taken to jones ford casa grande (1932 n pinal ave, casa grande, az 85122, (520) 836-3100) where it was diagnosed that the engine block was mixing with the oil. The vehicle was repaired. On another occasion, the power steering was locking consistently, and the interlock and advancetrac warning indicators illuminated. The failure recurred. The vehicle was taken back to the same dealer and was repaired again. The contact stated that the power assist warning indicator illuminated. The vehicle was towed to the same dealer where the gears and alignment were reset. The contact also mentioned that the check engine warning indicator continued to illuminate. The vehicle was taken back to the same dealer where it was determined that an unknown part needed to be replaced. The vehicle was repaired, but the failure continued. The contact stated that the fuel filter neck assembly also needed to be replaced. The evaporator canister was replaced and the technician informed the contact that the fuel tank was leaking fuel. The vehicle was not repaired because the fuel tank was no longer manufactured by ford. The contact stated that the vehicle remained at the dealer and was not repaired. The manufacturer was not made aware of the failures. The failure mileage was approximately 48,000.

Filed Oct 30, 2018 · Fuel system · 64,000 miles · VA

Car only has 64k but has started leaking fuel, especially when the fuel tank is full. Fuel leak appears to be near right rear wheel and dangerously close to exhaust pipe. Repair shop estimates $1000 to replace fuel pump.

Filed Feb 28, 2018 · Fuel system · 62,000 miles · MA

Fuel system leaks from the fuel pump assembly. Significant gas leak while vehicle was parked and tank full. Gas smell after driving vehicle. Pump is near the exhaust system and I believe there was a fire hazard. Vehicle has only 62k miles on it. It cost me $825 to repair. Ford has no tsb on it.

Filed Feb 14, 2017 · TX

We have experienced clearly discernible exhaust gas leaks into the cabin of the 2011 explorer, which are most noticeable when accelerating. We took the vehicle to the local dealership recently, and they implemented a tsb from ford that involved adding small vents in the rear door area. The dealership could not tell us if this would actually resolve the issue. And we have not driven the vehicle since that time, so don't yet know if the problem has been resolved by the tsb implementation.

Filed Apr 17, 2016 · Fuel system · 67,390 miles · NC

Gas leak driver side fuel tank at seam