2006 Ford Mustang Fuel System Problems

This has happened since purchasing my personal 2006 Mustang GT new in 2006. I also see early S-197 Mustangs (2005—2007) in my shop that cannot be reliably refilled because fuel shoots out of the filler neck, splashes the operator, the side of the Mustang, and puddles on the ground. The defective On-board Refueling and Vapor Recovery (ORVR) system causes high internal fuel tank pressures that will also cause the filling station pump to cut off and prevent putting fuel in the tank. This creates a fire hazard as the spillage contacts the left hot tail pipe and muffler as well as a puddle of fuel that can be ignited by a spark, cigarette, etc. This problem is in direct violation of the Environmental Protection Agency emission standards that clearly state the operator is “expected to fill the fuel tank without spit back or spillage during the refueling event.” EPA emission regulations also require that service vents, also known as safety and vacuum relief valves, be installed in tanks to prevent excessive pressure or vacuum that can build up “due to tank filling or emptying.” The parts of the Ford ORVR system that contribute to the fuel tank pressure spikes and fuel spills include: 1.Poor fuel filler design. The filler pipe is narrow (5/8” to 3/4”) with a severe an S-bend before it reaches the tank. There is a spring-loaded plug at the top of tank built into the fill neck that closes the fill pipe until fuel pushes the plug down to open the fuel tank. 2.Poor fuel tank design. The saddle style tank has two sections that “saddle bag” over the drive shaft making the opening between the two tanks very narrow and at the top of the tank. 3.Insufficient tank venting system. The capacity of this vent system is not sufficient to vent the fuel tank during refueling. Please see attached file that documents the problem and possible solutions. I also recommend sharing your many complaints on this problem with the EPA as the problem is also in their area.

THIS IS JUST THE RECENT EVENT. HAPPENS MORE THE HALF THE TIME WHEN FUELING VEHICLE. WHILE STATIONARY, NEWER MODEL MUSTANG HAVE A SPLIT FUEL TANK EACH HOLDING EIGHT GALLONS. ONE HALF ON DRIVER SIDE , OTHER HALF PASSENGER SIDE , UNDER THE BACK SEATS, THE DRIVERS SIDE WILL FILL AND THE PASSENGER SIDE WILL NOT TAKE ANY FUEL. THE PROBLEM OCCURS WHILE TRYING TO FILL THE PASSENGER SIDE. THE FUEL SPILLS ON THE GROUND . WHICH NOT ONLY CAUSES A FIRE PROBLEM , BUT MAYBE MORE IMPORTANTLY A SERIOUS ENVIRONMENTAL PROBLEM. I FOUND OUT ABOUT THIS PROBLEM FROM GOOGLING IT THINKING I MIGHT BE ABLE TO FIX IT OR IF I NEEDED A NEW TANK AND OR PARTS. WHAT I FOUND OUT WAS THIS A COMMON PROBLEM WITH THE SPLIT TANK. FIRE IS A DEADLY AND PAINFUL ACCIDENT TO HAPPEN. THE ENVIRONMENTAL IMPACT IS PERMANENT. MAYBE IT IS AN EPA PROBLEM.

WHILE DRIVING THE 5 SPD, TAKING OFF FROM STOP SIGN THERE IS A DEAD SPOT THEN IT TAKES OFF IRRADICALLY. ONCE ON THE INTERSTATE, I TRIED TO SLOW DOWN AND FOOTFEED STUCK SO I SHIFTED DOWN AND PUMPED THE FOOTFEED/PEDAL THAT WASN'T STUCK..THE MOTOR EVENTUALLY SLOWED DOWN TO A MANAGEABLE LEVEL. IT HAS SOMETHING WRONG WITH THE THROTTLE PEDAL ASSEMBLY SENSOR. HAS OTHERS COMPLAINED OF THIS? IT IS A RECALL SITUATION FORD IS WILLING TO TAKE CARE OF? I AM THE 3RD OWNER. THE FIRST TWO COMPLAINED IT WAS HARD TO TAKE OFF ON A HILL. BUT THAT CAN BE AN INEXPERIENCED DRIVER PROBLEM IS WHY I BOUGHT IT.

MY CAR IS SURGING EVEN WITH THE BRAKE ON OR A LOT OF TIMES IF I'M IN TRAFFIC IT WILL COMPLETELY DIE. THEN IT WILL START BUT WHEN PUT IN DRIVE IT CONTINUES TO DIE. I HAVE ALMOST BEEN HIT SEVERAL TIMES. I HAVE CLEANED SENSOR AND PUT NEW AIR FILTER ON ITU.

CAR STARTED TO STALL WHILE IN MOTION, APPLIED GAS AND WAS OK. AT NEXT STOP LIGHT, THE CAR STALLED OUT. AFTER TRYING TO START A FEW TIMES WHICH IT DID BUT IMMEDIATELY STALLED OUT. AFTER SITTING A FEW MINUTES, IT STARTED OK AND WAS FINE. LEFT CAR AT DEALER FOR 1 WEEK, THEY COULD NOT FIND ANYTHING WRONG. ON 8/15/15, THE WRENCH CAME ON TWICE AND THEN THE ENGINE CHECK LIGHT STAYED ON. THIS WAS AFTER A 215 MILLE DRIVE ON THE INTERSTATE. RETURNED TO DEALER WHO NOW HAD COMPUTER CODES. ELECTRONIC THROTTLE BODY NEEDED REPLACEMENT. PART LISTED ON BILL SAYS POTENTIOMETER FORD PART#6L2Z-9B989-D. THIS NOW EXPLAINS SUBTLE ACCELERATIONS THAT OCCURRED ON HIGHWAY WHEN IT WAS NOT ME APPLYING PRESSURE TO THE GAS PEDAL.

I WAS STOPPED COMPLETELY. THE TRAFFIC LIGHT CHANGED TO GREEN IN THE INTERSECTION. I PRESSED THE ACCELERATOR AND IT WENT ALL THE WAY TO THE FLOOR AND STAYED THERE. I FLEW THRU THE INTERSECTION AT TOP SPEED WITH THE BRAKE PUSHED AS HARD AS I COULD WITH NO DECELERATION AT ALL. I TRAVELED APPROXIMATELY 150 YARDS WIDE OPEN. I STOMPED THE GAS PEDAL AND TRIED TO GET IT TO RELEASE WITH NO LUCK. I FINALLY TURNED THE IGNITION OFF AND JUMPED A CURB TO GET IT STOPPED JUST BEFORE I WOULD HAVE REAR-ENDED A VEHICLE IN FRONT OF ME. FLAT SPOTTED 2 BRAND NEW FRONT TIRES. IT WAS TERRIFYING! IT COST ME $721.32 TO GET THE THROTTLE BODY REPLACED. AFTER I GOT HOME I GOOGLE FORD ACCELERATION PROBLEMS AND DISCOVERED THERE IS A CLASS ACTION SUIT IN 30 STATES AGAINST FORD FOR THE SAME THING THAT HAPPENED TO ME. THIS PROBLEM NEEDS TO BE CORRECTED AND I NEED A REFUND FROM FORD FOR THE DEFECTIVE THROTTLE BODY AND 2 NEW TIRES. *TR

CAR WILL NOT ACCEPT FUEL. WHEN TRYING TO PUMP GAS, IT SPILLS OUT ALL OVER THE SIDE AND ON ME. *TR

WHEN AT GAS STATION YOU CANT FILL UP THE GAS TANK WITHOUT IT SPITTING THE GAS BACK OUT. NOT EVEN FULL WHEN THIS IS HAPPENING. *TR

I AM A SENIOR THAT OWNS A 2006 MUSTANG CONVERTIBLE THE GAS TANK FILL HAS BACKED UP ON ME TWICE CAUSING A SKIN REACTION DEALER WHERE I PURCHASED CAR SAYS THERE IS NOTHING THE MATTER IT MAKES TRAVELING VERY UNSAFE AS I NEVER KNOW WHEN TANK WILL ALLOW A FILL-UP FORD SHOULD HELP WITH A SOLUTION I MAY HAVE TO GIVE MY CAR UP AS THERE DOES NOT SEEM TO BE ANY INTEREST IN CONSUMER COMPLAINTS. *TR

LATELY WHEN I TRY TO FILL UP MY 2006 MUSTANG THE GAS PUMP EITHER AUTOMATICALLY STOPS AROUND 1/2 TANK OR GAS GUSHES DOWN THE SIDE OF MY CAR AND ON THE GROUND WHEN TRYING TO FILL IT FULL. DEFINITE FIRE HAZARD ALONG WITH OTHER SAFETY ISSUES. LOOKED UP ONLINE AND THIS SEEMS TO BE A ISSUE WITH THOUSANDS OF MUSTANGS WITH THE S197 GAS TANKS. LETS DON'T LET A FIRE AT A GAS PUMP COST SOMEONE'S LIFE BEFORE WE MAKE FORD FIX THIS ISSUE. CAR IS OUT OF WARRANTY SO FORD WILL NOT FIX. *TR

WHEN I TRY TO PUT GAS IN MY CAR THE CAR WILL ONLY ALLOW ME TO PUT HALF OF A TANK IN THE CAR AND I HAVE TO FORCE IT TO TAKE MORE WHICH AS CAUSE THE GASOLINE TO OVERFLOW EVEN WHEN THE TANK IS NOT FULL. I HAVE TAKEN IT TO A DEALERSHIP AND TOLD ME ITS A KNOWN ISSUE BUT THEY COULD NOT FIX THE ISSUE FOR ME. THIS HAS HAPPENED IN THE PAST BUT NOW THE CAR WONT LET ME PUT MORE THEN A HALF TANK EVERYTIME. I HAVE TRIED TO GO TO VARIOUS GASOLINE STATIONS ALL DIFFERENT BRANDS TO SEE IF THERE ARE ANY DIFFERENCES BUT HAVE NOT HAD ANY SUCCESS. *TR

TL*THE CONTACT OWNS 2006 FORD MUSTANG. THE CONTACT STATED WHILE ADDING FUEL TO THE VEHICLE IT CONTINUED TO SPILL OUT OF THE FUEL TANK ON THE CONTACT AND ON THE GROUND. THE CONTACT TOOK THE VEHICLE TO THE DEALER REGARDING THE FAILURE AND THE DEALER FOUND A RESTRICTION BLOCKING THE FUEL TANK VENT LINE. THE VEHICLE WAS REPAIRED WHEN THE DEALER CLEARED THE VENT LINE. THE CONTACT STATED THE FUEL SPILL COULD HAVE CAUSED A FIRE. THE FAILURE MILEAGE WAS 23,450.

CANNOT EASILY PUT GAS IN TANK. THIS JUST STARTED OCCURRING AFTER HAVING 80,000 +/- MILES ON VEHICLE. THE DEALER STATED THAT THIS CAR HAD UPDATED (REMEDY) TANK INSTALLED DURING PRODUCTION, BECAUSE FORD KNEW OF PROBLEM ON 2005S. NEWER TANK WORKED SUCCESSFULLY FOR MANY MILES. GASSING UP IS NOW TOO FRUSTRATING TO DEAL WITH. I'VE BEEN A FORD FAN FOR MY ENTIRE LIFE, BUT THIS MIGHT CHANGE MY MIND. *TR

FORD MUSTANG 2006 - CAN NOT PUT GAS IN GAS TANK. WILL AUTOMATICALLY SHUT OFF WITHOUT PUTTING GAS IN TANK -- GAS JUST SPILLS ONTO YOUR FEET -- CREATING A SAFETY HAZARD. FORD KNOWS OF THIS PROBLEM - THERE IS A SERVICE BULLETIN & MANY COMPLAINTS. FORD SAYS THERE IS "NO FIX". SUGGESTS GETTING GAS AT DIFFERENT GAS STATION. I HAVE HAD CAR TO FORD SERVICE 4 TIMES -- SO FAR SPENT $300 ON SUPPOSED FIXES. NOW THEY SAY THERE IS NO FIX. SO - I HAVE A CAR, WITH 20,000 MILES ON IT, THAT I CAN NOT DRIVE. MUST STAY CLOSE TO HOME, JUST IN CASE I CAN'T GET ANY GAS INTO IT. SO FAR HAVE FOUND ONE GAS STATION WHERE I CAN PUT IN GAS IN THE CAR. FORD IS OBVIOUSLY NOT WORKING ON THIS PROBLEM SINCE IT HAS BEEN KNOWN FOR MANY YEARS -- THE COPY OF FORD SERVICE BULLETIN THAT I HAVE IS DATED 2007 -- THE SERVICE BULLETIN TSB 07-21-12 - STATES THAT THE PROBLEM CAN BE IMPROVED BY USING A DIFFERENT GAS STATION. THIS IS UNACCEPTABLE. LOCAL FORD DEALER JUST SHRUGS THEIR SHOULDERS AND GIVES ME A COPY OF SERVICE BULLETIN THAT SAYS THERE IS NO FIX. TIRED OF HAVING GAS SLOSH ONTO MY FEET AND THE SIDE OF THE CAR. *TR

2006 MUSTANG GT MANUAL TRANSMISSION. REPLACEMENT OF BATTERY RESULTS IN ENGINE STALLING WITH AIR CONDITIONING ON WHEN CLUTCH DEPRESSED.. THE OWNERS MANUAL STATES ON REPLACING BATTERY THE COMPUTER NEEDS TO RELEARN IDLE. THIS DOES NOT WORK AT LEAST NOT IN A REASONABLE AMOUNT OF TIME. THE VEHICLE HAS BEEN DRIVEN OVER A NUMBER OF DAYS WITH NO IMPROVEMENT. WITH THE AIR CONDITIONER RUNNING AND DEPRESSING THE CLUTCH EITHER COMING TO STOP OR TURNING A CORNER THE ENGINE IDLE WILL DROP FAR ENOUGH WHERE THE VEHICLE WILL STALL RESULTING IN A LOSS OF POWER STEERING AND POWER BRAKES POSSIBLY CREATING A DANGEROUS SITUATION. THE VEHICLE RAN CORRECTLY BEFORE THE BATTERY REPLACEMENT AND ONLY HAS 22,000 MILES. GOOGLING THIS ISSUE ON THE INTERNET FINDS NUMEROUS PROBLEMS WHICH ARE IDENTICAL OF WHICH OWNERS OF THE 4.6L FORD V8 (NOT JUST MUSTANG) ARE REPORTING IDLE AND STALLING PROBLEMS AFTER REPLACING THE BATTERY AND WITH THE ISSUE NOT RESOLVING ITSELF AS THE OWNERS MANUAL STATES RESULTING IN EITHER A COMPUTER REFLASH OR THROTTLE BODY REPLACEMENT. THIS DEFECT COULD RESULT IN A CRASH CAUSING SERIOUS INJURY OR DEATH. FORD SHOULD RECALL AFFECTED VEHICLES AND HAVE THE DEFAULT IDLE SETTING SET FOR A HIGHER VALUE SO THE AIR CONDITIONER WHEN ENGAGED DOES NOT RESULT IN THE ENGINE STALLING. THE IDLE OF ENGINE IS ERRATIC WITH THE AIR CONDITIONER ON SINCE IT IS ENGAGING AND DISENGAGING DUE TO THE LOW IDLE SPEED < 500RPM. BY NOT USING THE AIR CONDITIONER THE IDLE SPEED WILL RETURN TO ITS NORMAL SPEED OF AROUND 600 TO 700RPM BUT STILL FLUCTUATES SLIGHTLY. NOT BEING ABLE TO USE THE AIR CONDITIONER IS NOT ACCEPTABLE, ESPECIALLY IN THE SOUTH EAST. THE CONTROL FEED BACK OF THE IDLE SYSTEM IS INCORRECTLY OPERATING WITH THE AIR CONDITIONER LOAD ON IT. *TR

2006 MUSTANG GT- FUEL SENDER NEEDS REPLACEMENT. TROUBLE CODE P0456 COMES UP. THE FUEL PUMP ON VEHICLES BUILT BEFORE JANUARY 1ST, 2006 HAD AN OVERSIZED ORIFICE AND WOULD CAUSE A LEAK IN THE EVAPORATIVE SYSTEM. THE FUEL PUMP ITSELF WILL NOT BE AT DANGER FOR A FAILURE ALTHOUGH WITH AN EVAP CODE YOU MAY LOSE FUEL ECONOMY DUE TO THE TANK NOT BEING PROPERLY PRESSURIZED. ALSO YOU WILL NOT PASS A 'SMOG' TEST WITH THIS CODE. *TR

I HAVE A 2006 FORD MUSTANG AND I CONTINUOUSLY HAVE PROBLEMS PUTTING GAS INTO THE VEHICLE, EVEN WHEN IT IS NEAR EMPTY. THE GAS WILL SPLASH BACK OUT AND NOT GO INTO THE TANK. THIS HAS HAPPENED NUMEROUS TIMES AND JUST AS RECENT AS JUNE 6, 2010. I ALSO HAD AN INCIDENT AROUND MARCH OF 2010 WHEN I TRIED TO STOP FOR A STOP LIGHT AND MY CAR ACCELERATED WHILE I WAS LITERALLY STANDING ON THE BRAKE. I ALMOST HIT THE CAR IN FRONT OF ME AND WAS STOPPED BY POLICE FOR HAZARDOUS DRIVING. WHEN I EXPLAINED WHAT HAD HAPPENED, I DID NOT RECEIVE A CITATION BUT HAD TO GO ACROSS A CURB AND STAND ON THE BRAKE WHILE PULLING THE EMERGENCY BRAKE TO GET THE CAR TO STOP. THIS WAS VERY FRIGHTENING AND DANGEROUS TO MYSELF AND THE PEOPLE AROUND ME. *TR

MY 2006 MUSTANG HAS STARTED ONLY ALLOWING 5-9 GALLONS OF GAS TO BE PUT IN WHEN IT IS WARM OUTSIDE. IT STARTS SPITING GAS BACK OUT OF THE TANK. I GET GAS ALL DOWN THE SIDE OF THE CAR AND ALL OVER ME. THIS IS VERY DANGEROUS. WE CAN GET MORE GAS IN AT NIGHT WHEN IT IS COOLER OUTSIDE. *TR

2006 MUSTANG 4.0 OPERATED AT 68 MPH FOR 22 MILES. CAME TO INTERSECTION AND STOPPED. ACCELERATED WHILE TURNING INTO TRAFFIC AND VEHICLE HESITATED AND ENGINE DIED. I WAS NEARLY HIT BY TRACTOR TRAILER RIG BROADSIDE AT 50 + MPH. NHTSA AND FORD MOTOR CO. ARE AWARE OF THIS DEFECT AS PER TSB 06-9-9 WHICH ADVISES TO REPLACE ORIGINAL FUEL PUMP WITH 7R3Z-9H307-C FUEL PUMP AT THE EXPENSE OF THE VEHICLE OWNER. THIS IS A SAFETY ISSUE NOT A TSB ISSUE! SOMEONE WILL BE KILLED BY THIS DEFECT! IT ALSO IS NOT IN SAFETY'S INTEREST TO EXPECT VEHICLE OWNERS TO SPEND MORE THAN $300.00 OUT OF POCKET FOR THIS REPAIR WHEN MANY OWNERS WILL DELAY THIS EXPENSE. THIS DEFECT SHOULD DEFINITELY BE HANDLED AS A RECALL ! *TR

HESITATION IN GAS PEDAL/THROTTLE BODY. WHEN TRYING TO PULL OUT INTO TRAFFIC I WOULD EASE DOWN ON GAS PEDAL WITH NO REACTION UNTIL ABOUT HALF THROTTLE AND THE CAR WOULD JUMP AT ABOUT HALF THROTTLE AND I WOULD THEN HAVE TO LET OFF GAS PEDAL AND REPEAT PROCESS UNTIL UP TO SPEED OF APPROXIMATELY 30 MPH. AFTER THE FIRST INCIDENT THIS BECAME A RE-OCCURRING PROBLEM. VERY DANGEROUS SITUATION. EVERYONE I TALK TO ABOUT THIS SAYS IT IS A COMMON PROBLEM WITH THIS MODEL, 2005-2014 FORD MUSTANG. I HAVE 3 OF THEM AND THEY ALL HAVE THE SAME PROBLEM.