2004 Ford F-150 fuel system problems

What is wrong

Ford is recalling certain 1997 through 2003 model year ford f-150, 2004 model year ford f-150 heritage, 1997 through 1999 model year f-250 less than 8,500 lbs. Gross vehicle weight rating (gvwr), and 2002 and 2003 lincoln blackwood vehicles manufactured from june 20, 1995, through august 4, 2004, originally sold, or currently registered in, connecticut, delaware, illinois, indiana, iowa, kentucky, maine, maryland, massachusetts, michigan, minnesota, missouri, new hampshire, new jersey, new york, ohio, pennsylvania, rhode island, vermont, west virginia, wisconsin, and the district of columbia. Prolonged exposure to road deicing chemicals may cause severe corrosion of the fuel tank straps which secure the tank to the vehicle.

Risk

As a result of the corrosion, one or both straps may fail allowing the fuel lines to separate from the tank, or in some cases, causing the tank to contact the ground. Either scenario may result in a fuel leak presenting a fire hazard.

Remedy

Ford will notify owners and instruct them to take their vehicles to a ford or lincoln dealer to have the fuel tank straps replaced with straps that have increased corrosion protection. Early in this campaign, if replacement straps are not available, dealers may install a cable support under the strap as an interim repair or a steel reinforcement over the existing strap as a permanent repair. Any repairs will be performed free of charge. The safety recall began on september 16, 2011. Owners may contact ford motor company customer relationship center at 1‑866‑436‑7332. Ford's recall campaign number is 11s21

Recall number 11V385000 · Recall details

What is wrong

On certain trucks equipped with 4.2l, 4.6l and 5.4l gasoline engines, the fuel tank may have a depression at the seam between the top and bottom halves of the tank. If a depression is large enough, fuel may permeate the fuel tank wall resulting in a fuel odor, illumination, of the "service engine soon" indicator light, or a fuel leak.

Risk

Fuel leakage, in the presence of an ignition source, could result in a fire.

Remedy

Dealers will replace the fuel tank. The recall began september 17, 2004. Owners should contact ford at 1‑800‑392‑3673.

Recall number 04V443000 · Recall details

What is wrong

Certain pickup trucks may have a fuel tank with localized depressions in the fuel tank wall at the seam between top and bottom halves of the tank. If a depression is large enough, fuel may permeate the fuel tank wall resulting in a fuel odor, or the "service engine soon" indicator light in the instrument cluster may illuminate.

Risk

If left uncorrected, a fuel leak could eventually develop.

Remedy

Dealers will replace the fuel tank on these vehicles. Owner notification began on may 6, 2004. Owners should contact ford at 1‑800‑248‑0186.

Recall number 04V200000 · Recall details

One or both of the steel straps holding up the fuel tank and attaching it to the truck frame can corrode and fail (break or separate).If one strap fails, the tank may tilt and drop and possibly contact the road surface.If both straps break, the entire tank may drop to the road.If either failure occurs while the vehicle is being driven, contact with the road can abrade the tank and create a hole from which gasoline can spill.When the tank drops, it remains attached to the vehicle only by the fuel filler hose and/or supply lines, or in rare instances, by the skid plate, if present.In some cases the weight of the tank sufficiently strained the hoses and fittings and caused separation and subsequent fuel leaks from those connections.The fire hazard created by leaking gasoline is increased by the possible presence of sparks created by the metal tank being dragged along the road.Corrosion of the straps appears to be caused by prolonged exposure to road deicers, frequently road salt, used to treat snow or ice covered roads.States in which large quantities of deicers are applied to roads during the winter season (salt belt states) account for the predominant portion of strap failures.Vehicles in these salt belt states are prone to experience corrosion related failures more frequently and earlier in a vehicle?s life cycle.Ford reports approximately 97 percent of reports it received relating to strap failure involve vehicles that were operated in these high corrosion areas, and 95 percent of the reports to the federal safety agency involved such vehicles.Approximately one-third of F-150 U.S. production was sold in salt belt states.ODI has included in the above counts reports it has received from consumers and reports it has received from Ford in which either the complaint involved confirmed strap corrosion or ODI's assessment of available information suggests corrosion caused the reported problem.Among the incidents reported to the federal safety agency, 441 involved one or both straps failing due to corrosion, 353 involved the fuel tank dropping and/or dragging on the ground, and 180 involved fuel leakage.ODI has received four reports of strap failure in which the leaking fuel ignited but self-extinguished, and one incident in which fire destroyed the vehicle and injured its driver.Ford reported the same injury incident and three other unique fire incidents, including two in which the leaking fuel ignited and fire destroyed the vehicle.There were no injuries associated with the three unique Ford incidents.Ford has agreed to conduct a recall to repair the subject vehicles.The recall will cover vehicles that were originally sold or are currently registered in salt belt states (regardless of vehicle age).The vehiclesincluded in the recall are those subject vehicles that are, or have ever been, registered in Connecticut, Delaware, Iowa, Illinois, Indiana, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin, or the District of Columbia.Ford's recall action appears to adequately address the problem at this time.The above vehicle population (1,340,349) includes subject vehicles originally delivered or sold in salt belt states.ODI does not know the current or historical locations of all subject vehicles.According to Ford approximately 73% of the recall population is currently registered (a 27% attrition rate).Ford is also recalling certain MY 1997-1999 F-250 vehicles (under 8,500 GVWR), and MY2002-2003 Lincoln Blackwood vehicles for the same condition, resulting in an estimated 1.1 million total vehicles

EA11006

The agency has closed this investigation based on its review of complaint reports, discussions with complainants and field and technical data provided by ford.the subject vehicles are 1/2 ton pickup trucks and are natural gas vehicles (ngv) that are fueled by gasoline or compressed natural gas.the agency has received reports alleging improper operation of the natural gas fuel pressure regulator allowing release of excess amounts of natural gas into the engine compartment.ford reports that the regulator contains an over pressure relief valve that will vent natural gas should the pressure exceed a set threshold.the complaint reports and data reviewed by the agency indicate that an improperly operating pressure regulator can result in an overpressure condition and activate the regulator pressure relief valve.the released natural gas is directed through a vent hose that discharges the natural gas in the vicinity of the right front wheel house and away from the engine compartment's extremely hot areas/surfaces.owners are normally aware of this problem by the presence of an illuminated warning light inside the vehicle, odor of natural gas or the sound of venting gas.when the operator turns the engine off, the natural gas supply tank solenoid will close and the regulator will not release natural gas.at vehicle restart, the solenoid valve will remain closed to prevent leakage and the vehicle will only operate in the gasoline mode.a safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.accordingly, this investigation is closed.the closing of this investigation does not constitute a finding by the federal safety agency that a safety-related defect does not exist.the agency will monitor this issue and reserves the right to take further action if warranted by the circumstances.

PE08063