2005 Ford E350 Fuel system Problems

The contact owned a 2005 Ford E-350. The contact stated while driving approximately 45 MPH he smelled a burning odor and saw that the vehicle was trailing a large white cloud. The contact stated no warning light was illuminated. The contact pulled over and as soon as he exited the vehicle it had become engulfed in flames. The contact stated that the flames came from under the rear of the vehicle. The vehicle burned, the contact stated the fire department was not able to locate his vehicle and later the police had called him and left a voice message advising him that the vehicle had been towed to an impound lot. The manufacturer had not been informed of the failure. The contact had researched online and related the failure to NHTSA Campaign Number: 11E047000 (Fuel System, Gasoline). The failure mileage was approximately 145,000.

NHTSA ID

11553413

Incident

Nov 2, 2023

Mileage

145,000 mi

ONLY 87000 MILES AND THE FUEL TANK IS SHEDDING SILVER PAINT FLAKES, INTO THE FUEL SYSTEM.. HAVE NOW REPLACED ALL THE FILTERS TWICE, PUMP ONCE.. AND THE TANK PRE FILTER HAS TO BE CLOGGED AS NO FUEL WILL EVEN COME OUT.. HAD BEEN A VERY GOOD TRUCK, BUT THIS ENGINEERING CAUSES THE VAN TO JUST DIE!! ON THE ROAD. THIS IS APPARENTLY A COMMON PROBLEM AND ONE THAT FORD AND THEIR ENGINEERS ARE NOT BEING RESPONSIBLE FOR.. REALLY... PAINT INSIDE AT FUEL TANK? WTF ARE THEY THINKING...

NHTSA ID

11355011

Incident

Sep 2, 2020

Mileage

87,000 mi

TL* THE CONTACT OWNS A 2005 FORD E-350. WHILE DRIVING VARIOUS SPEEDS, THE VEHICLE SUDDENLY STALLED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE FUEL INJECTION CONTROL MODULE FAILED. THE CONTACT REPLACED THE CONTROL MODULE, BUT THE FAILURE CONTINUED. UPON INSPECTION, THE CONTACT DETERMINED THAT THE FUEL INJECTION CONTROL MODULE WIRE HARNESS FAILED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE CONTACT WAS INFORMED THAT THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 05V270000 (ELECTRICAL SYSTEM). THE FAILURE MILEAGE WAS 90,000.

NHTSA ID

10913614

Incident

Jun 1, 2016

Mileage

90,000 mi

WHILE DRIVE ON HIGHWAY,VEHICLE BEGAN TO LOSE POWER WHEN I ENCOUNTERED A HILL. IT BOGGED DOWN AND STRUGGLED TO MAKE IT TO TOP OF HILL AND LOST SPEED DOWN TO 30 MPH OR LESS AND THEN DIED. IT WOULD NOT START RIGHT AWAY, BUT AFTER LETTING IT SIT FOR 15 MINUTES, IT STARTED AND HAD REGAINED POWER AND I DROVE IT TILL I GOT TO THE NEST HILL AND DID THE SAME THING SEVERAL TIMES TILL I MADE IT HOME 3 HOURS LATER FOR A 10 MILE TRIP. I CHECKED ONLINE ON THE VEHICLE FOR FORD OWNERS FORUM AND SAW THAT SEVERAL PEOPLE ENCOUNTERED THIS PROBLEM BEFORE AND DESCRIBED IT AS BOGGING DOWN AND LOSING POWER. SOME ONE SUGGESTED CHANGING THE EGR VALVE WHICH I HAD DONE, AND THE FUEL FILTERS AS WELL AS AIR FILTER. WHEN I REMOVED THE BOTTOM FUEL FILTER UNDER THE VAN, I CAPTURED THE FUEL IN THE FILTER AND LINE AND IT HAD WHAT LOOKED LIKE SILVER PAINT. I KEPT THE SAMPLE AND IT IS SOFT AND PLIABLE. I ASSUMED IT WAS A PROTECTIVE COATING LINING THE FUEL TANK. I DON'T BELIEVE THIS SHOULD BE HAPPENING,BECAUSE IT COULD DO DAMAGE TO THE INJECTORS AND OTHER THINGS. *TR

NHTSA ID

10659991

Incident

Oct 17, 2014

Mileage

141,008 mi

TL* THE CONTACT OWNS A 2005 FORD E-350. THE CONTACT STATED THAT HE NOTICED FUEL LEAKING FROM THE FUEL TANK. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR DIAGNOSIS. THE MECHANIC STATED THE FUEL TANK WOULD HAVE TO BE REPLACED BECAUSE IT WAS CORRODING AND LEAKING FUEL. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 103,000. *TR

NHTSA ID

10524948

Incident

Jul 4, 2013

Mileage

103,000 mi

TL* THE CONTACT OWNS A 2005 FORD E-350 SD. WHILE DRIVING UPHILL APPROXIMATELY 25 MPH, THERE WAS A SIGNIFICANT REDUCTION IN ENGINE POWER. THE FAILURE WAS CONSTANT. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHO ADVISED THAT THE FUEL TANK LINER HAD DETERIORATED. THE TECHNICIAN ALSO INFORMED THE CONTACT THAT THE FUEL TANK, FUEL PUMP AND INJECTORS WOULD NEED TO BE REPLACED. IN ADDITION, THE FUEL FILTERS WOULD REQUIRE REPLACEMENT. THE MANUFACTURER WAS NOTIFIED OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 82,867.

NHTSA ID

10483617

Incident

Nov 2, 2012

Mileage

82,867 mi

TL* THE CONTACT OWNS A 2005 FORD E350 SUPER DUTY. THE CONTACT STATED THAT HE WOULD HAVE TO WAIT HOURS FOR THE ENGINE TO COOL DOWN BEFORE THE VEHICLE COULD BE STARTED. THE VEHICLE WAS TAKEN TO A DEALER FOR DIAGNOSIS AND THE CONTACT WAS INFORMED THAT THE ENGINE OIL COOLER, INJECTORS AND THE EGR COOLER WOULD ALL NEED TO BE REPLACED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC AND WAS REPAIRED. THE MANUFACTURER WAS NOTIFIED BUT OFFERED NO ASSISTANCE. THE FAILURE AND CURRENT MILEAGE WAS 79,000. UPDATED 1/7/13 *CN THE CONSUMER STATED THE DEALER REBUILT THE ENGINE, POSSIBLY DUE TO DETERIORATION OF THE FUEL TANK LINER. UPDATED 01/09/13

NHTSA ID

10483539

Incident

Aug 31, 2012

Mileage

79,000 mi

TL*THE CONTACT OWNS A 2005 FORD E-350. THE CONTACT STATED THAT THE VEHICLE WOULD INTERMITTENTLY STALL WHILE DRIVING AT LOW SPEEDS. THE VEHICLE WAS ALSO EXPERIENCING A LOSS OF POWER AND THE ENGINE WOULD NOT FUNCTION NORMALLY. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE THE CONTACT WAS TOLD THAT THE FUEL SYSTEM WAS EXPERIENCING DELAMINATION. THE VEHICLE WAS REPAIRED. THE FAILURE MILEAGE WAS 113,386 AND THE CURRENT MILEAGE WAS UNKNOWN.

NHTSA ID

10392629

Incident

Aug 30, 2010

Mileage

113,386 mi

IN JANUARY 2009, ENGINE BEGAN RUNNING ROUGH. TOOK TO FORD DEALER, AND THEY TESTED FUEL SYSTEM. DIAGNOSED RUST IN FUEL DUE TO FUEL TANK RUSTING AND REPLACED FUEL TANK AND FILTERS. DECEMBER 2010, THE ENGINE BEGAN RUNNING ROUGH AGAIN. TOOK VEHICLE TO NON FORD REPAIR, AND WAS DIAGNOSED THAT FUEL TANK WAS DELAMINATING AND HAD CLOGGED FILTERS, AND INJECTORS. WILL NEED TO REPLACE FUEL TANK, FUEL FILTERS, AND INJECTORS. *TR

NHTSA ID

10372715

Incident

Jan 4, 2009

Mileage

82,574 mi

MY MECHANIC DESCRIBED AND CONFIRMED THE SYMPTOMS IN NHTSA #10022243, WHERE THE LINING OF THE FUEL TANK IS SEPARATING FROM THE TANK AND CLOGGING THE FUEL FILTER AND FUEL PUMP. THIS CAUSES LOSS OF POWER PRIMARILY ON THE FREEWAY. IT CONSISTENTLY GETS WORSE WHERE IT HAPPENS EVERY FEW MINUTES. THE REPAIRS OTHERS HAVE MADE HAVE BEEN TO GET A NEW TANK OR BOIL OUT AND RE-COAT THE DEFECTIVE TANK. I PLAN TO BOIL IT OUT AS THAT IS THE ONLY OPTION I CAN AFFORD. *TR

NHTSA ID

10349719

Incident

Jul 25, 2010

Mileage

105,000 mi

TL* THE CONTACT OWNS A 2005 FORD E350 DIESEL ENGINE. WHILE DRIVING AT UNKNOWN SPEEDS, THE CHECK ENGINE LIGHT ILLUMINATED ON THE WARNING PANEL AND THE VEHICLE STALLED. THE CONTACT STATED THAT THE FAILURE WOULD OCCUR INTERMITTENTLY AND THE VEHICLE HAD BEEN TAKEN TO THE DEALER SEVERAL TIMES. THE DEALER MADE REPAIRS TO THE FUEL TANK, FUEL PUMP, HIGH PRESSURE FUEL SENSOR PUMP AND THE OIL PRESSURE PUMP. IN ADDITION, THE FUEL INJECTOR WAS REPLACED FIVE TIMES IN AN ATTEMPT TO CORRECT THE STALLING FAILURE. ON A SEPARATE DATE, THE VACUUM PUMP WAS REPLACED AS WELL. THE MANUFACTURER STATED THAT THE FAILURE WAS DUE TO THE QUALITY OF GASOLINE THE CONTACT HAD CHOSEN TO PUT INTO THE VEHICLE. THE FAILURE MILEAGE WAS 21,000 AND THE CURRENT MILEAGE WAS 143,000.

NHTSA ID

10323850

Incident

Jan 4, 2006

Mileage

21,000 mi

SILVER FLAKES IN FUEL FILTERS CAUSED BY KNOWN DELAMINATION OF FUEL TANK CAUSING FAILURE OF FUEL PUMP AND TRANSMISSION TROUBLE. FORD HAD KNOWN OF PROBLEM FOR OVER 4 YEARS AND HAS NOT MADE IT KNOW TO OWNERS OF THESE VEHICLES. REQUEST RECALL! *TR

NHTSA ID

10318044

Incident

Mar 8, 2010

Mileage

132,000 mi

SUDDEN FUEL LEAK FROM FUEL FILTER MOUNTING HOUSING RESULTING IN SIGNIFICANT DOWN TIME AND EXPENSE. *TR

NHTSA ID

10314676

Incident

Jun 20, 2009

Mileage

130,000 mi

VEHICLE WAS REGULARLY MAINTAINED BE AN OWNER WHO HAS HAD EXPERIENCE WITH AND OWNED DIESEL VANS FOR OVER 20 YEARS. THE FAILURE OCCURS WHILE DRIVING ON THE HIGHWAY, WHEN AVERAGE SPEEDS ARE AROUND 60 MPH AFTER DRIVING FOR ABOUT FIFTEEN MINUTES. WHILE DRIVING, THE ENGINE BEGINS TO STEADILY LOSE POWER AND SPEED CONSISTENTLY DECREASES. THIS WILL LEAD THE DRIVER TO HASTILY CHANGE LANES TO ATTEMPT TO GET TO THE SHOULDER BEFORE THE VAN STOPS IN THE MIDDLE OF THE ROAD. ONCE ON THE SIDE OF THE ROAD, THE ENGINE WILL CUT OFF ONCE THE VEHICLE HAS COME TO A STOP AND WILL NOT START UP AGAIN FOR 10-20 MINUTES. OTHER TIMES THE VEHICLE WILL NOT START UP AGAIN AND WILL NEED TO BE TOWED. ONCE THE FAILURE STARTED FOR THE FIRST TIME, IT WOULD REPEAT THIS FAILURE ONCE EVERY OTHER WEEK, THEN ONE WEEK, THEN A FEW TIMES A WEEK, THEN ALMOST EVERYDAY. THE CONSEQUENCES, FOR EXAMPLE, WAS WHEN THE ENGINE FAILED AND LOST POWER I HAD TO HASTILY TRY TO GET TO THE NUMBER 3 LANE FROM THE NUMBER 1 LANE DURING MORNING RUSH HOUR, WHICH ENDANGERS EVERYONE ON THE ROAD. AFTER GETTING TO THE SIDE, I ATTEMPTED TO TURN INTO AN EXIT WHEN THE WHEELS LOCKED AND ENGINE CUT OFF. THE FRONT HALF OF THE VAN WAS DIRECTLY IN THE WAY OF ONCOMING TRAFFIC, ALMOST HITTING A CAR AND CAUSING A MASSIVE BACKUP BECAUSE THE VAN CANNOT MOVE. THE CONSEQUENCES OF THIS FAILURE IS THOUSANDS OF DOLLARS IN FALSELY ATTEMPTS AT FIXING THE PROBLEM FROM THE FORD DEALERSHIP. THE VEHICLE WAS TAKEN TO THE DEALERSHIP FOR REPAIRS A TOTAL OF FIVE TIMES BY WHICH THE FIFTH ONE THE DEALERSHIP WANTED $2000 DOLLARS TO REPLACE THE GAS TANK BECAUSE OF PARTICULATES FROM THE COATING OF THE TANK ERODED AND DESTROYED THE FUEL SYSTEM. THE FIRST SAID IT WAS THE FUEL INJECTORS, THEN FUEL PUMP, THEN TWO ADDITIONAL FUEL PUMPS, THEN CHARGED $1000 FOR AN ENGINE FLUSH. THE VAN WAS IN THE SHOP FOR APPROX. 25 DAYS TO WHICH NOTHING WAS RESOLVED. WE ARE CURRENTLY TAKING LEGAL ACTIONS TO PAY FOR COSTS OF UNNECESSARY REPAIRS, RENTAL FEES, AND THE DAYS UNABLE TO WORK. *TR

NHTSA ID

10252367

Incident

May 1, 2008

Mileage

46,838 mi

2005 FORD E350 WITH SEVERAL PROBLEMS. CONSUMER WOULD LIKE REIMBURSEMENT FOR THE FOLLOWING REPAIRS. ENGINE WOULD NOT START, FUEL LEAK ON THE PASSENGER SIDE, FUEL LEAKING FROM THE INJECTORS AND FUEL RAIL LEAK ON SEVERAL OCCASIONS. *KB THE FUEL PUMP ALSO FAILED. *JB

NHTSA ID

10218289

Incident

Nov 30, 2007

Mileage

31,681 mi

6.0 POWER STROKE, MANY PROBLEMS SINCE NEW . PURCHASED IN AUG, 05 *JB

NHTSA ID

10189128

Incident

Apr 9, 2007

Mileage

29,000 mi

CARTER COUNTY EMERGENCY AMBULANCE SERVICE HAS A TOTAL OF 10 FORD E350 FORD AMBULANCES. THREE OF THE 2005 THAT WE PURCHASED LAST JULY BEEN NOTHING BUT PROBLEMS. HIGH PRESSURE PUMP AND INJECTORS, THREE AMBULANCES AND A TOTAL OF 220 DAYS OF DOWN TIME ON THIS PROBLEM. (TRIED TO GET HELP FROM FORD BUT TO NO VAIN.) ALL TEN OF OUR AMBULANCES ARE FORDS BUT THE THREE 2005 MODELS ARE THE ONLY ONES THAT HAVE GIVEN US ANY TROUBLE. *JB

NHTSA ID

10168268

Incident

Sep 15, 2005

Mileage

37,000 mi