2011 Ford Explorer Fuel System Problems

The fuel sending unit goes bad due to the split tank and differential and drive train have to be taken apart and dropped in order to change. Costing over $1,000.00. You can not go under half a tank of gas and if you do you just run out of gas immediately causing you to stop on highways side roads etc.Its very dangerous to have a vehicle that will just all of a sudden run out of gas and no one is paying to get them fixed because of the pricepoint charged to repair. This is Fords faulty work 1000%

The contact owns a 2011 Ford Explorer. The contact stated that while driving at an undisclosed speed, the contact detected an abnormal fuel odor. The vehicle was taken to an independent mechanic, who diagnosed that there was a vapor leak coming from the top of the fuel tank. The vehicle was not repaired. The manufacturer was made aware of the failure and advised the contact to file a complaint with the NHTSA Hotline. The failure mileage was approximately 102,000.

9/25/22 My 2011 Ford Explorer xlt would start jerking when pushing on the gas paddle and then would start losing speed or power. Today is the third day this has happened so I looked on YouTube and entered my symptoms of my car and it suggested it could be my (electronic position sensor). And YouTube told me there is an extended warranty on this part. I have 140000 miles this vehicle. This vehicle has not been inspected or confirmed by a dealership as of yet. There was no warning when this problem began and no warning lights on the dashboard. I am very hesitant in driving this vehicle around town , fearing it may stop completely.

No warning when the fuel relay gasket attached to the pump assembly fails and allows fuel vapor to fill the cabin of the car. Owner safety is at risk of possible fire. I know of 2 Ford dealerships that are aware of the safety hazard.

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). *TR

The vehicle has been in for service at Downs Ford Dealership twice in the past two years for the same issue and has yet to be resolved. When the gas tank is filled with gas, there is overwhelming smell of gas that doesn’t get better until the tank is about half full. The first time the car was in for service, I was told that the gas tank needed to be replaced but they were having trouble finding one. They said to take the car home and they would call when they found one but they never called. The vehicle was brought in a 2nd time to fix the issue in July of 2021. At that time we were told a valve needed to be replaced and charged $500 but it has not fixed the issue. I’m frustrated and tired of wasting $ and time without my car when they don’t seem to be able to fix it. Consumer would like to would like to withdraw the complaint.

TL* THE CONTACT OWNS A 2011 FORD EXPLORER. THE CONTACT STATED THAT THERE WAS AN ABNORMAL FUEL ODOR COMING FROM THE PASSENGER SIDE. THE CONTACT BECAME NAUSEAS FROM BREATHING IN THE FUMES AND THEIR NOSE BURNED FROM THE INSIDE, WHICH WAS A DISTRACTION TO THE CONTACT'S HEALTH AND CONCENTRATION DURING DRIVING. MEDICAL ATTENTION WAS NOT RECEIVED. THE CONTACT CALLED BOWDITCH FORD OF HAMPTON (11291 JEFFERSON AVE, NEWPORT NEWS, VA 23601, (800) 735-2211) WHERE AN APPOINTMENT WAS SCHEDULED FOR JULY 19, 2019. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 67,480.

TL* THE CONTACT OWNS A 2011 FORD EXPLORER. WHILE DRIVING VARIOUS SPEEDS, A STRONG ODOR OF NATURAL GAS WAS DETECTED COMING FROM THE AIR VENTS. WHEN THE CONTACT EXITED THE VEHICLE, THE ODOR WAS ALSO NOTICED AROUND THE PERIMETER OF THE VEHICLE. IN ADDITION, ALL THE WINDOWS WERE FOGGY. THE CONTACT STATED THAT THE FUEL ODOR WAS STRONGER WHEN THE HEAT WAS ACTIVATED. THE VEHICLE WAS TAKEN TO LESTER GLENN SUBARU (1501 RTE 37 W, TOMS RIVER, NJ 08755, (888) 785-0675) WHERE THE CONTACT WAS INFORMED THAT THE O-RING INSIDE THE FUEL LINE NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED, BUT THE FAILURE RECURRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 72,000.

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.

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.

EXHAUST FUMES ENTER CABIN DURING HARD ACCELERATION. CONDITION HAS EXISTED SINCE NEW IN MAY OF 2011. A/C ON OR OFF, RECIRCULATION ON OR OFF. REQUIRES ROLLING DOWN WINDOWS TO REMOVE FUMES. CONDITION CAN BE DUPLICATED AT ANY TIME.

SINCE I PURCHASED BY 2011, NEW IN 2011, I HAVE NOTED A STRONG SMELL OF GAS IN THE CABIN OF THE CAR UPON EXCELERATING TO MERGE INTO TRAFFIC ON THE HIGHWAY. THE SMELL WILL LINGER AND REQUIRES NECESSITY TO CRACK MY WINDOWS TO CLEAR. I HAVE ADDRESSED THIS WITH MY LOCAL FORD SERVICE CENTER TWICE, BUT THEY HAVE HAD NO ANSWERS. IN THE PAST TWO YEARS, UPON RE-ENTERING THE VEHICLE AFTER DRIVING AND PARKING, I HAVE NOTED A PUNGENT SMELL SIMILAR TO SCORCHED HAIR INTERMITTENTLY. CONCERNED ABOUT EXHAUST FUMES AND POTENTIAL CARBON MONOXIDE POISONING.

TL* THE CONTACT OWNS A 2011 FORD EXPLORER. THE CONTACT STATED THAT THE CONTACT'S VEHICLE WAS REAR ENDED BY ANOTHER VEHICLE. THE CONTACT ALSO STATED THAT A STRONG FUEL ODOR WAS PRESENT IN THE VEHICLE AFTER THE CRASH OCCURRED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED AND REPAIRED; HOWEVER, THE CONTACT COULD NOT PROVIDE INFORMATION ABOUT WHAT COMPONENT FAILED AND NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 37,000. UPDATED 01/26/2017*CT UPDATED 7/11/18*JB

WE HAVE HAD ISSUES WITH SMELLING EXHAUST IN THE CABIN OF THE VEHICLE. IT HAPPENS WHEN TAKING OFF FROM A STOP OR ACCELERATING SUDDENLY. WE HAVE NOTICED THIS FOR A WHILE NOW AND IT HAS HAPPENED MANY TIMES. WE KNOW YOU ARE INVESTIGATING THE ISSUE BUT WANTED TO LET YOU KNOW WE ARE EXPERIENCING THE ISSUE ALSO. WE HAVE LESS THAN 55,000 MILES ON THE VEHICLE.

GAS LEAK DRIVER SIDE FUEL TANK AT SEAM

TL* THE CONTACT OWNS A 2011 FORD EXPLORER. WHILE DRIVING APPROXIMATELY 2 MPH, THE ODOR OF EXHAUST FUMES FILLED THE VEHICLE WITHOUT WARNING. THE VEHICLE WAS TAKEN TO A LOCAL DEALER WHERE IT WAS DIAGNOSED THAT THE VEHICLE WAS OUT OF WARRANTY. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND OFFERED TO PAY A PORTION OF THE REPAIR COST. THE FAILURE WAS REMEDIED, BUT RECURRED LATER. THE VEHICLE WAS TAKEN BACK TO THE DEALER AWAITING FURTHER DIAGNOSIS. THE FAILURE MILEAGE WAS APPROXIMATELY 50,000.

I AM NOT CERTAIN WHERE TO FULLY POST THIS OR WHAT CAN HAPPEN FOR THIS CAR. I GAVE THIS CAR BACK TO WESTLIE FORD IN CAMAS, WA. IT WAS CONFIRMED BY A DOCTOR THAT 3 PEOPLE GOT SULFUR POISONING FROM THIS CAR. I SAW THIS CAR INSTANTLY BACK ON FORDS LOT EVEN THOUGH I HAD ADVISED THEM IT GAVE ME SULFUR POISON. WHEN MY FRIEND EMAILED INQUIRING ABOUT THE CAR THEY ADVISED THAT THE CAR HAD NOT BEEN CHECKED BUT WAS A KEEPER. THEY CAR WAS A LEMON FROM THE START AND EVEN THOUGH I HAD THE CAR FOR 7 MONTHS IT HAD BEEN IN THE SHOP FOR ABOUT 2 MONTHS OF THAT TIME PERIOD FOR DIFFERENT REPAIRS. WE ALSO INQUIRED ABOUT THAT WITH EVERYTHING ON THE CAR FAX REPORT. THEY CAME BACK THAT IT WAS JUST BASIC MAINTENANCE. 7 ISSUES IN 7 MONTHS WAS NOT BASIC FIXES. THE OTHER MAJOR THING BESIDE SULFUR POISON WAS THE CAR WAS LEAKING AND HAD MILDEW ISSUES BEFORE I FOUND THE LEAK. I AM JUST WORRIED ABOUT THE NEXT FAMILY THAT GETS IN THIS CAR. IF IT HASN'T BEEN PROPERLY FIXED THE NEXT PERSON CAN HAVE THE SAME ISSUES AS MY FAMILY. *TR

WHEN FILLING THE GAS TANK THE GAS NOZZLE WOULD SHUT OFF. EVEN WHEN I WAS VERY SLOWLY PUMPING IN GAS , THE PUMP WOULD SHUT OFF VERY MUCH LIKE A TANK INDICATING IT WAS FULL WHICH I KNOW WAS NOT THE CASE. THEN GAS WOULD DRIP/STREAM (NUMEROUS DRIPS AND STREAMS)) UNDER THE VEHICLE CREATING A BASKETBALL SIZE GAS SPOT. UPON SERVICE AT THE DEALER I WAS TOLD THE TANK VENT TUBE WAS BLOCKED BY COBWEBS. DRIVING FOR OVER 50 YEARS , I HAVE NEVER HEARD OF SUCH A THING. *TR

TL* THE CONTACT OWNS A 2011 FORD EXPLORER. WHEN THE FUEL TANK WAS FILLED TO CAPACITY, THE FUEL GAUGE INDICATED ONLY A HALF OF A TANK. THE CONTACT STATED THAT THE CHECK ENGINE WARNING INDICATOR ILLUMINATED AFTER THE FUEL TANK WAS FULL. THE VEHICLE WAS TAKEN TO A DEALER, BUT WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 23,000.

VEHICLE GAS TANK WAS FILLED. FUEL GAUGE SHOWED 3/4 FULL - AFTER A BRIEF DRIVE (LESS THAN 20 MILES) VEHICLE WAS STARTED AND FUEL GAUGE SHOWED LESS THAN HALF A TANK. VEHICLE WAS PUT IN SHOP FOR REPAIR. ON 9/17 - IT WAS PICKED UP ON 9/20 - TRUCK WAS FILLED UP AGAIN ON 9/23 AND FUEL GAUGE AGAIN SHOWED 3/4 FULL.