2009 Ford F-150 Fuel System Problems

Exhaust gas is leaking into cab from manifold, because several studs broke

GAS GAUGE SUDDENLY DOESN'T REGISTER CORRECTLY. ONLY SHOWS APPROXIMATE THREE QUARTERS TANK WHEN TANK IS FULLY FILLED. WHEN REGISTERING ONE QUARTER TANK ONLY TAKES $15- TO $16 TO REFUEL. REPAIR SHOPS HAVE NOT BEEN ABLE TO DETERMINE CAUSE. WHAT CAN BE THE CAUSE.

MY VEHICLE SIMPLY STALLED WITHOUT WARNING WHILE I WAS TRAVELING ON THE HIGHWAY, TWICE. AFTER A SMALL COOL DOWN PERIOD, THE VEHICLE STARTED UP AGAIN AND SEEMED FINE TILL A FEW DAYS LATER WHEN IT HAPPENED AGAIN ON THE HIGHWAY. ACCORDING TO FORD, THIS IS A VERY COMMON PROBLEM WITH A FUSE THAT CONTROLS THE FUEL PUMP. IT OVERHEATS AND FAILS CAUSING THE FUEL PUMP TO STOP WORKING. THEY ALSO HAVE A $20 KIT TO FIX THE PROBLEM BECAUSE IT IS SO COMMON. WHY THIS IS NOT A RECALL IS BEYOND ME. MY WIFE AND I COULD HAVE BEEN SERIOUSLY HURT OR WORSE.

VEHICLE ONLY HAS 4,000 MILES. COMPLETE FUEL LINE FAILED ACCORDING TO DEALER AND WAS DRIPPING GASOLINE ON EXHAUST FROM ENGINE TO TANK. IT WAS SMOLDERING AND ALMOST IGNITED OVER THE WEEKEND. FIRST NOTICED STRONG GASOLINE SMELL IN CAB. INSPECTION STATION NOTICED LEAK AND WAS TOWED TO DEALER. THEY ARE SPECIAL ORDERING PARTS. TRUCK IS AT PARK CITIES FORD 3333 INWOOD ROAD, DALLAS, TX 214-358-8800.

WHILE PASSING A SLOW MOVING VEHICLE THE THROTTLE STUCK AND ALTHOUGH NO PRESSURE WAS ON THE GAS PEDAL, IT KEPT ACCELERATING. BY HEAVY USE OF THE BRAKE, I WAS ABLE TO RETURN TO TOWN, WHERE I SHUT THE ENGINE DOWN. IT IS STILL LOCKED ON, AS WHEN I START IT, THE RPM'S JUMP TO 4000 IMMEDIATELY. I HAVE CALLED THE FORD DEALERSHIP AND REQUESTED A TOW. THIS WAS FRIGHTENING, AS I HAD MY GRANDSON IN THE VEHICLE WITH ME.

THIS HAS OCCURRED MANY TIMES. THE VEHICLE STALLS WHEN SLOWING DOWN DUE TO THE FUEL PUMP INSIDE THE FUEL TANK GETTING BENT UPWARD DUE TO THE TANK COLLAPSING ON ITSELF BECAUSE IT IS NOT DESIGNED TO VENT PROPERLY. I HAVE ALREADY REPLACED THE FUEL PUMP BUT IT ONLY CORRECTED THE PROBLEM TEMPORARILY BECAUSE IT HAS BEEN BENT AS WELL OVER A SHORT PERIOD OF TIME. THE GAS GAUGE READS IMPROPERLY AS WELL DUE TO THE PUMP NOT REACHING THE BOTTOM OF THE TANK. I CAN ONLY FIT ABOUT 17 GALLONS INTO A 30 GALLON TANK UPON REFILLING. THE STALLING THAT THIS CAUSES HAS ALMOST CAUSED ME TO HAVE MULTIPLE ACCIDENTS. I HAVE RESEARCHED THIS PROBLEM AND HAVE FOUND MANY OTHER OWNERS TO HAVE THE SAME PROBLEM AND HAVE HAD ACCIDENTS. FORD REFUSES TO CORRECT THE PROBLEM WITHOUT CHARGING. IT IS VERY EXPENSIVE TO HAVE THE FUEL PUMP REPLACED AND THAT DOES NOT FIX THE PROBLEM. THIS IS A DESIGN PROBLEM THAT FORD NEEDS TO REPAIR. PLEASE REQUIRE FORD TO RECALL AND FIX THIS DESIGN FLAW BEFORE SOMEONE ELSE IS KILLED OR INJURED.

SLOWING TO MAKE A RIGHT TURN, THE ENGINE FELL DEAD. I WAS ABLE TO START IT AND PULL OUT OF TRAFFIC BEFORE IT FELL DEAD AGAIN. NUMEROUS TIMES AFTER I FILL UP, THE ENGINE WAS HARD TO START. IT SPUTTERED AND STALLED AND FINALLY STARTED. I TOOK THE VEHICLE TO THE DEALERSHIP SERVICE DEPARTMENT BUT THEY WERE UNABLE TO FIND ANYTHING WRONG. THIS HAPPENS WITHOUT WARNING AND COULD CAUSE CRASHES IF NOT REPAIRED.

MY ENGINE LIGHT CAME ON THE CODE READ BAD FUEL PUMP MODULE. *TR

TL - THE CONTACT OWNS A 2009 FORD F-150. THE CONTACT STATED THAT UPON REFUELING THE VEHICLE, FUEL WOULD SPEW FROM THE FILLER NECK WITHOUT WARNING. THE VEHICLE WAS TAKEN TO A DEALER WHERE THE FAILURE WAS UNABLE TO REPLICATED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 46,000. THE CURRENT MILEAGE WAS 51,335. RK

ON OR ABOUT AUG & 2013 THE VEHICLE MENTION ABOVE WOULD START AND THEN STALL . I TOOK THE FORD F150 TO PALM BAY FORD IN PALM BAY FL. I WAS VISITING MY STEPSON AT THE TIME. I AM FORM GA. THE FORD DEALER HAD IT FOR 3 DAYS AND SAID THAT THERE WAS NOTHING WRONG. ON FEB 7 2014 THE SAME THING HAPPEN. THIS TIME THEY TOWED THE FORD TO THERE PLACE FROM MY STEPSONS HOME. THEY HAD THE VEHICLE FOR 3 DAYS. AND FINALLY SAID THAT THE FUEL PUMP DRIVER MODULE HAD FAILED. I CANNOT BELIEVE THAT THEY WOULD NOT KNOW THE FIRST TIME THIS HAPPEN. THEY CHARGED ME 652.09 FOR THE REPAIR. I KNOW THAT I AM NOT THE FIRST PERSON THIS HAS HAPPEN TO. WHAT WOULD HAVE HAPPEN IF THIS MODULE FAILED WHEN I WAS ON INTERSTATE 95. THIS COULD HAVE CAUSED AND ACCIDENT OR WORSE. FORD SHOULD RECALL THIS DEVICE BECAUSE OF THE FAILURE OF THE MODULE AND WHERE IS PLACED(UNDER THE SPARE TIRE) AND THE TWO DIFFERENT METALS THAT CAUSE CORROSION. *TR

FIRST, THE FUEL DOOR FELL OFF THE TRUCK. LATER THAT EVENING I HEARD A WEIRD SUCTION SOUND COMING FROM THE FUEL DOOR AREA. IT BEGAN TO IDLE ROUGH, THEN WOULD NOT WANT TO START AFTER FILL UPS. WHEN YOU WOULD STICK THE GAS NOZZLE IN THE TANK A LOUD "WHOOSH" SOUND WOULD EMIT AS IT RELIEVED PRESSURE. MY GAS GAUGE STOPPED FUNCTIONING AND ALL OF THESE ISSUES EVENTUALLY LEADING TO THE TANK IMPLODING/COLLAPSING ON ITSELF. THIS BENT THE FUEL PUMP AND GAS GAUGE INSIDE THE TANK. I PAID OUT OF POCKET TO HAVE IT FIXED BECAUSE THE FORD DEALERSHIP TOLD ME THE WARRANTY ONLY "COVERED MOVING PARTS". I ASKED IF THE FUEL GAUGE FLOAT AND FUEL PUMP MOVED. THEY ENJOYED MY RHETORIC, BUT DECLINED TO FIX THE PROBLEM. THEY ONLY REPLACED A SENSOR THAT THREW A LEAN BANK ONE CODE AND CAUSED THE CHECK ENGINE LIGHT TO COME ON. I DROVE IT FOR THE NEXT YEAR OR SO USING THE ODOMETER TO TELL ME WHEN TO FILL UP AS MY GAS GAUGE NO LONGER WORKED.. FAST FORWARD A YEAR AND A HALF, AND RUNNING OUT OF GAS 3 OR 4 TIMES, AND IT HAS DONE THE SAME THING TO ME AGAIN. I JUST PAID $972.19 TO A PRIVATE GARAGE TO REPLACE THE FUEL PUMP, BUT I ONLY GOT A 90 DAY WARRANTY ON THE WORK AND NO GUARANTEE THAT THIS ISSUE WILL NOT HAPPEN AGAIN. WHEN I GOOGLED THE MAKE AND MODEL OF THE TRUCK I FOUND ALL KINDS OF INFORMATION ABOUT PEOPLE HAVING THE SAME PROBLEM, YET FORD ACTED LIKE THEY HAVE NEVER HEARD OF THIS BEFORE. I UNDERSTAND I AM RESPONSIBLE FOR KEEPING THE TRUCK RUNNING, BUT NOTHING ABOUT THE WAY I OPERATE THE VEHICLE MADE IT DO THIS. IF I GET IN A WRECK, I SHOULD PAY TO FIX IT. THIS IS A DESIGN FLAW AND SHOULD BE RECALLED. BTW I WAS DOING 70 MPH ON THE INTERSTATE WHEN IT SHUT DOWN MOST RECENTLY AND TRAFFIC HAD ME BOXED IN. IT NEARLY CAUSED A COLLISION JUST GETTING IT OFF THE ROAD. HAD I DIED, NO ONE WOULD HAVE QUESTIONED WHAT CAUSED THE ACCIDENT. *TR

TL* THE CONTACT OWNS A 2009 FORD F-150. THE CONTACT STATED THAT WHILE DRIVING 40 MPH THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS TAKEN TO THE DEALER WHO DIAGNOSED THAT THE BATTERY WAS DEFECTIVE AND THAT THE VEHICLE RAN OUT OF FUEL. THE VEHICLE WAS TAKEN TO ANOTHER DEALER WHO DIAGNOSED THAT THE FUEL TANK HAD COLLAPSED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE WHO STATED THAT THEY WOULD CONTACT HIM BACK AT A LATER DATE. THE VEHICLE WAS REPAIRED. THE FAILURE AND THE CURRENT MILEAGE WAS 52,000.

THE FAN BLOWER SPEED CONTROL STUCK ON HIGH ONLY AND WAS REPLACED 09/2011. THE VEHICLE KEPT STALLING OUT UPON DECELERATION GOING DOWN THE ROAD. WITH LOSS OF POWER STEERING AND POWER BRAKES WHEN THIS HAPPENS. COULD BE GOING 30 MPH OR 60 MPH. WHEN GET MOTOR IS STARTED AGAIN IT USUALLY RUNS ROUGH. THE LEFT OXYGEN SENSOR CODE WAS ON SO THIS WAS REPLACED. 11/2011 THE FUEL GAUGE ALSO STOPPED READING FUEL IN THE TANK WHEN THIS HAPPENS. REPLACED FUEL PUMP IN TANK, FUEL FILTER, FUEL POWER MODULE, ALL WAS FINE FOR THREE WEEKS. TRUCK DIES 8 TIMES TODAY AND ALL THE SAME PROBLEMS ARE BACK. ENGINE LIGHT ON, FUEL GAUGE STOPPED WORKING, TRUCK RUNS ROUGH FOR AWHILE WHEN RESTARTED THEN CLEARS UP. ENGINE LIGHT NOW STAYS ON AND FUEL GAUGE WILL READ 1/2 TANK WHEN IT IS FULL. 36 GAL TANK. 11/22/2011. *TR

**CATASTROPHIC FUEL TANK FAILURE** TWO DAYS AGO MY 2009 F150 DIED IN MY DRIVEWAY, IT ACTED AS IF OUT OF FUEL EVEN THOUGH THE GAGE READ OVER HALF A TANK. I HAD IT TOWED TO A FORD DEALER AND WAS INITIALLY INFORMED THAT THE TRUCK WAS OUT OF GAS AND THE FUEL GAGE WASN'T WORKING. A NEW UNIT WAS ORDERED AND ONCE THE TANK WAS REMOVED FROM THE TRUCK IT WAS DISCOVERED THAT THE ISSUE WAS EXCEEDINGLY MORE SEVERE. THE MECHANIC AND A FORD ENGINEER CONCLUDED THAT THE CHARCOAL PURGE VALVE FAILED AND THE FUEL PUMP CREATED SUCH A STRONG VACUUM THAT THE FUEL TANK COLLAPSED ON ITSELF AND CRUSHED THE FUEL PUMP.ALTHOUGH THE TRUCK HAS ONLY 15,000 MILES IT IS NOT A WARRANTY REPAIR DUE TO A SALVAGE TITLE ON THE VEHICLE. AFTER THE INSPECTION IT WAS CONCLUDED THAT THE FUEL TANK UNIT WAS NOT DAMAGE OR EFFECTED BY ANY INCIDENT AND WAS IN STANDARD OPERATING CONDITION WHEN THE EVENT OCCURRED.I ALSO UNDERSTAND THAT SINCE THIS IS NOT A WARRANTY REPAIR, FORD WILL NOT BE COLLECTING THE PARTS FOR FURTHER EVALUATION. I BELIEVE THIS TO BE A MISTAKE! I HAVE ASKED TO KEEP THESE PARTS AND WILL PROVIDE THEM TO FORD IF NEED BE. AS AN ENGINEER I BELIEVE THIS TO BE A DESIGN FLAW THAT COULD PRESENT A SEVERE SAFETY HAZARD. *TR

MY 2009 FORD F150 SUFFERS ENGINE STALL WHEN STOPPING IN TRAFFIC. THERE ARE NO DIAGNOSTIC INDICATIONS (ENGINE LIGHT, CODES STORED). IT HAS A "LIFETIME" FUEL FILTER, SO IT CANNOT BE CHANGED. WHEN THE ENGINE STALLS, POWER STEERING AND POWER BRAKES ARE LOST, RESULTING IN POSSIBILITY OF ROLLING INTO ONCOMING TRAFFIC. I HAVE SUFFERED 3 NEAR MISSES IN THE PAST 3 DAYS. FORD WILL NOT ACCOMMODATE MY SCHEDULE FOR SERVICE. *TR

I STOPPED AT THE MOBIL KANAGROO EXPRESS GAS STATION IN GAINESVILLE TO FILL MY 2009 FORD F150 UP WITH GAS. I USED THE HANDLE LOCK ON THE GAS NOZZLE TO FILL THE TANK. I ALSO HELD IT WITH MY HAND. WHEN IT WAS NOT YET FULL THE NOZZLE FLEW OUT OF THE FILLER TUBE SPRAYING GASOLINE ALL OVER ME AND THE GROUND. I PULLED THE TRUCK AWAY FROM THE GAS PUMPS BECAUSE I WAS WORRIED ABOUT A FIRE. I WENT INTO THE STORE EXPLAIN TO THE CLERK WHAT HAPPENED AND TOLD HIM THAT HE HAD A PROBLEM OUT AT THE PUMP BECAUSE THERE WAS A PUDDLE OF GASOLINE STILL ON THE GROUND. I HAD A CHANGE OF CLOTHES WITH ME AND THE CLERK GAVE ME A BAR OF SOAP TO WASH UP WITH. THE CLERK SAID THE GAS AT THE PUMP WOULD JUST EVAPORATE. I ALSO REPORTED THE INCIDENT TO THE GAINESVILLE FIRE DEPARTMENT WHO SAID THEY WOULD CHECK THE STATIONS PUMPS. I DON'T KNOW WHETHER IT WAS THE FAULT OF THE TRUCK OR THE GAS PUMP BUT I WAS AFRAID OF DYING BECAUSE I WAS COVERED IN GASOLINE. *TR