RoadVitals

2005 Ford Explorer Fuel system Problems

Owner-reported complaints naming the fuel system system, filed with NHTSA

Data refreshed

Fuel system reportsComplaints are reports submitted to NHTSA by owners and drivers. NHTSA does not verify most reports before publishing them, and a complaint does not establish that a defect exists. Volume is influenced by how many of a vehicle were sold, how long it has been on the road, and how much attention an issue has received.
66
Latest Aug 19, 2020
Share of all reportsThis category as a share of every owner report on file for this model year. One report can name more than one component, so the categories overlap.
13%
of 497 total
Crash or fire reportedReports in this category whose submitter recorded that a crash or a fire occurred. The reporter's own answer on the NHTSA form, not a verified finding.
1
Injuries or deaths reportedTotals the submitters entered on their own reports in this category. Not verified by NHTSA and not a casualty statistic.
0

What this page shows

Reports naming fuel storage or delivery — tanks, pumps, lines, injectors and fuel leaks. Every record below is an owner-reported complaint about the 2005 Ford Explorer submitted to NHTSA — not a confirmed defect, not a recall and not a manufacturer bulletin. 66 reports on file name it.

Complaints are reports submitted by owners and drivers to NHTSA. They are not verified and do not establish that a defect exists.

Owner reports naming fuel system

The 25 most recent of 66, in the owner's own words

ElectricalEngineFuel system
Filed Aug 19, 2020

TL* THE CONTACT OWNS A 2005 FORD EXPLORER. THE CONTACT STATED THAT SHORTLY AFTER REFUELING, THE VEHICLE FAILED TO ACCELERATE WITH THE ACCELERATOR PEDAL DEPRESSED. THE CONTACT STATED THAT THE VEHICLE THEN ABRUPTLY ACCELERATED AT A HIGH RATE OF SPEED WITHOUT THE ACCELERATOR PEDAL BEING DEPRESSED. ALSO, THE LOW OIL PRESSURE WARNING LIGHT AND CHECK TRANSMISSION WARNING LIGHT WAS ILLUMINATED. THE CONTACT STATED THAT THEY WERE CLOSE TO HOME SO THEY PULLED INTO THE DRIVEWAY TO CHECK THE OIL LEVEL, WHICH WAS LOW. THE CONTACT TOOK THE VEHICLE TO A CERTIFIED MECHANIC WHO DIAGNOSED THAT THE ENGINE BEARING NEEDED TO BE REPAIRED DUE TO DAMAGE CAUSED BY A DEFECTIVE OIL SENSOR NOT PROPERLY INFORMING THE CONTACT WHEN THE OIL LEVEL WAS LOW. THE VEHICLE WAS NOT REPAIRED. THE CONTACT CONTACTED THE DEALER CAPITAL CITY FORD LOCATED AT 8623 E. WASHINGTON ST, INDIANAPOLIS, IN 46219) WHO INFORMED THE CONTACT THAT THERE WERE NO RECALLS ON THE VEHICLE. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 250,406. INVALID VIN.

NHTSA ID
11350238
Incident
Jul 12, 2020
Mileage
250,406 mi
Fuel system
Filed Apr 4, 2018

TAKATA RECALL. FUEL GAUGE STOPPED WORKING CHANGED THE FUEL PUMP IN THE TANK 2 TIMES STILL DID NOT WORK. CHECKED FOR GROUND CONNECTIONS ALL SEEMED WELL. THE FUEL GAUGE STILL DOES NOT WORK

NHTSA ID
11083350
Incident
Apr 3, 2018
Fuel system
Filed Aug 25, 2017

WE'VE REPLACED THE FUEL SENSOR IN OUR 2005 FORD EXPLORER XLT TWICE IN THE PAST TWO YEARS. WE HAD 68,000 MILES WHEN WE FIRST REPLACED THE FUEL SENSOR. IT IS A COSTLY FIX. NOW, AUGUST 2017, THE FUEL SENSOR IS NOT WORKING AND OUR SERVICE ENGINE SOON LIGHT IS ON. THIS IS A SAFETY ISSUE BECAUSE WE NEVER KNOW HOW MUCH GAS WE HAVE IN THE TANK. THE GAS GOES UP AND DOWN AND IS NOT RELIABLE. THE COMPUTER NEVER STATES THE CORRECT NUMBER OF MILES TILL EMPLY. I'LL BE DRIVING ALONG AND THE GAUGE GOES DOWN TO EMPTY AND THE COMPUTER STATES -------.

NHTSA ID
11019597
Incident
May 20, 2016
Mileage
68,000 mi
Fuel system
Filed Aug 23, 2017

FUEL GAUGE DROPS TO EMPTY AFTER FILLING THE TANK UP AND STARTING IT. THE FUEL GAUGE REMAINS ON EMPTY. SERVICE ENGINE LIGHT COMES ON AND STAYS ON. IT IS UNSAFE NOT KNOWING HOW MUCH FUEL IS IN THE TANK BECAUSE YOU COULD RUN OUT OF GAS AT 70+MPH AND CAUSE A CRASH. SEARCHING THE ISSUE ONLINE BROUGHT ME TO HUNDREDS OF 2002-05 FORD EXPLORER OWNERS WITH THE SAME EXACT PROBLEM. FORD MOTORS SHOULD PUT OUT A RECALL FOR THIS ISSUE BECAUSE IT IS EXTREMELY DANGEROUS.

NHTSA ID
11019251
Incident
Aug 23, 2017
Mileage
47,000 mi
Fuel system
Filed Dec 30, 2016

THROTTLES BODY ASSY. STALL OR SURGE WHILE ENTER IN TRAFFIC MAKE VERY DANGER

NHTSA ID
10938681
Incident
Sep 1, 2016
Fuel system
Filed Oct 20, 2016

WHEN TRYING TO FILL THE GAS TANK IT IS SLOW AND WILL NOT FILL PROPERLY. HAD 3 DIFFERENT MECHANICS TRY TO FIX THE PROBLEM WITH NO RESOLVE.

NHTSA ID
10917670
Incident
Jun 20, 2007
Mileage
45,000 mi
Driver assistanceFuel system
Filed Jun 25, 2015

DRIVING DOWN THE ROAD, SUDDENLY THE WRENCH LIGHT CAME ON AND THE FAIL SAFE LIGHT CAME UP. VEHICLE WOULD BARELY RUN. CLEANED THROTTLE BODY AND IT SEEMED FINE FOR A WHILE. THEN THE SAME THING HAPPENED AGAIN, DRIVING NORMAL, THEN BAM. THIS TIME IT SHUT DOWN AND WOULD BARELY STAY RUNNING...JUST ORDERED A NEW THROTTLE BODY. I WILL NOT OWN ANOTHER FORD.

NHTSA ID
10730484
Incident
Jun 22, 2015
Mileage
86,000 mi
Fuel system
Filed Apr 16, 2015

IN THE LAST TWO WEEKS THE FUEL GAUGE WILL GO FROM FULL( WHEN THE TANK IS FULL)TO EMPTY THEN THE LOW FUEL ALERT CONTINUES TO SOUND.... TODAY APR 16 2015 THE TRUCK STARTED SPUTTERING THEN SHUT OFF IN THE MIDDLE OF A HIGHWAY AT 65MPH..... IT STARTED AFTER 3 TRIES I TOOK IT TO GAS STATION AND IT'S FULL OF GAS BUT GAUGE SAYS IT'S EMPTY ..... THIS ISN'T SAFE ..... MY 2 YR OLD COULD HAVE BEEN IN AN ACCIDENT.... WHY ISN'T IT BEING RECALLED ? IF YOU GOOGLE THE PROBLEM IT'S UP TO $2000 TO FIX AND EVERYONE IS HAVING THIS PROBLEM BUT NO INVESTIGATION OR RECALL. *TR

NHTSA ID
10706107
Incident
Apr 6, 2015
Fuel system
Filed Apr 10, 2015

CANNOT FILL GAS TANK WITHOUT NOZZLE OR PUMP CONSTANTLY SHUTTING OFF. HAVE TO BEARLY SQUEEZE NOZZLE AND TRICKLE THE GAS IN. TAKES 10 TIMES LONGER TO FILL TANK THAN IT SHOULD. SOUNDS LIKE A VERY COMMON PROBLEM WITH OLDER FORDS. *TR

NHTSA ID
10704872
Incident
Jan 5, 2015
Mileage
145,000 mi
Fuel system
Filed Apr 7, 2015

TL* THE CONTACT OWNS A 2005 FORD EXPLORER. WHILE REFUELING THE VEHICLE, FUEL SPEWED OUT OF THE FUEL TANK AS IF IT WERE FULL. THE CONTACT STATED THAT FUEL SPILLED ONTO HIS CLOTHING AND THE VEHICLE. THE FAILURE RECURRED NUMEROUS TIMES. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 98,000.

NHTSA ID
10704149
Incident
Apr 15, 2013
Mileage
98,000 mi
Fuel system
Filed Mar 26, 2015

WHENEVER I FILL UP WITH GAS THE GAS GAUGE GOES TO EMPTY AND THE MILE TO EMPTY NUMBERS BECOME TWO BLANK SPACES AND THE CHECK ENGINE LIGHT COMES ON. *TR

NHTSA ID
10701909
Incident
Jan 9, 2012
Fuel system
Filed Mar 17, 2015

FILLED TANK TO FULL (AUTOMATIC SHUT OFF). WHEN I STARTED CAR THE NEXT TIME, GAS GAUGE READ EMPTY AND CHECK ENGINE LIGHT WAS ON. I HAVE HAD THE MALFUNCTION OF GAUGE BEFORE AND HAS ALWAYS COME BACK AFTER A FEW MILES, BUT NEVER LIGHT. AFTER GETTING ERROR LIGHT READ, IT IS DETERMINED TO BE A FAULTY FUEL SENSOR. THIS CAN BE A SAFETY HAZARD AS THERE IS NO WAY FOR THE VEHICLE TO DISPLAY THE FUEL CORRECTLY WHEN THE SENSOR MALFUNCTIONS. I MAKE SURE NOT TO OVERFILL THE TANK AS FORD WARNS THAT THIS COULD BE AN ISSUE, WHICH SHOULD HAVE BEEN FIXED (NOT JUST THAT THEY KNOW IT CAN HAPPEN). EVEN BY FOLLOWING THE MANUFACTURER'S PRECAUTIONS, THE PART STILL FAILED. *TR

NHTSA ID
10694740
Incident
Mar 14, 2015
Mileage
56,000 mi
Fuel system
Filed Mar 3, 2015

FUEL GAUGE IS WORKING INTERMITTENT. TANK IS FILL UP WITH GAS, BUT GAS GAUGE SHOW EMPTY. SOMETIMES IT COMEBACK, AFTER AN HOUR OR SO AND THEN, AFTER 30 MINS GOES BACK TO EMPTY AGAIN. I READ THIS IS AN ISSUE ON ALMOST ALL FORD EXPLORER. *TR

NHTSA ID
10691966
Incident
Oct 20, 2010
Mileage
55,000 mi
Fuel system
Filed Sep 12, 2014

TL* THE CONTACT OWNS A 2005 FORD EXPLORER. THE CONTACT STATED THAT WHILE DRIVING AT 35 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS ABLE TO RESTART. THE FAILURE OCCURRED ON SEVERAL OCCASIONS. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE FUEL FILTER NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED BUT THE FAILURE PERSISTED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 65,000.

NHTSA ID
10632875
Incident
Feb 1, 2013
Mileage
65,000 mi
Fuel system
Filed Feb 14, 2014

TL-THE CONTACT OWNS A 2005 FORD EXPLORER. THE CONTACT STATED THAT SHE FILLED THE FUEL TANK UP AND THE LET THE VEHICLE SIT OVER NIGHT. THE CONTACT STATED THAT THE FOLLOWING MORNING SHE WENT TO START THE VEHICLE BUT THE FUEL TANK WAS VERY CLOSE TO EMPTY. THE VEHICLE WAS NOT TAKEN TO THE DEALER FOR INSPECTION. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS UNKNOWN. AP *TR

NHTSA ID
10564319
Incident
Jun 8, 2012
EngineFuel systemPowertrain (other)
Filed Feb 12, 2014

CAR SUDDENLY QUIT AND THE ENGINE FAIL SAFE LIGHT CAME ON. COMPUTER SCAN SHOWED THE THROTTLE ACTUATOR/CONTROL WAS STUCK CLOSED, AND COULD CLEAR ANY CODES. VEHICLE WOULD NOT MOVE AT ALL.. I HAD TO HAVE IT TOWED BACK TO MY HOME. ENGINE WOULD NOT RUN AT MORE THAN AN IDLE WITH THE ACCELERATOR FULLY DEPRESSED, AND THERE WOULD BE NO CHANGE IN THE RPM. *TR

NHTSA ID
10564141
Incident
Feb 10, 2014
Mileage
126,341 mi
ElectricalEngineFuel system
Filed Jan 21, 2014

HAD FUELED (FULL) 2 HOURS BEFORE. GAS GAUGE DROPPED TO EMPTY. MILES TO EMPTY SHOWS DASHES. SERVICE ENGINE SOON LIGHT IS ON. *TR

NHTSA ID
10560784
Incident
Jan 16, 2014
Mileage
165,000 mi
Fuel system
Filed May 21, 2013

"CHECK ENGINE" LIGHT CAME UP, BUT THE CAR DID NOT SHOW ANY DIFFERENCE IN PERFORMANCE. I TOOK TO ADVANCED AUTO AND THEY SAID THE "GAS TANK SENSOR FAILED". I CHECKED WITH A LOCAL MECHANIC AND HE SAID IT WOULD BE MAJOR JOB AND COULD TAKE MORE THAN 6 HOURS LABOR THE ESTIMATE WAS OVER $1000. BUT THE CAR IS RUNNING FINE, BUT THE "CHECK ENGINE " IS ON CONSTANTLY AND IT GOES OFF WHEN THE TANK IS ALMOST EMPTY. WHEN I PUT GAS, IT COME BACK ON AGAIN AND STAYS ON. GAS TANK NEEDLE DROPS TO EMPTY SUDDENLY AND IT GOES UP AGAIN. I CHECKED WITH MIDAS AUTO REPAIR AND THEY CHECKED AND SAID THE SAME PROBLEM OF GAS SENSOR FAILURE. IT IS ANNOYING TO SEE THE CHECK ENGINE LIGHT ALWAYS ON, BUT THE CAR SEEMS TO RUN FINE. ANY CHEAPER WAY TO GET THIS FIXED? I DON'T HAVE ANY MECHANICAL SKILLS, OTHER THAN CHANGING THE AIR-FILER. I THINK FORD SHOULD FIX THIS FREE OF CHARGE. *TR

NHTSA ID
10512966
Incident
Feb 12, 2013
Mileage
88,500 mi
Fuel system
Filed Feb 11, 2013

FILLED UP THE GAS TANK THE DAY BEFORE AND NOW THE GAS METER ON THE DASHBOARD READS EMPTY. I KNOW THERE'S GAS ON THE CAR. NOW THE "SERVICE ENGINE SOON" LIGHTS APPEARS ON THE DASHBOARD. I'M AFRAID TO DRIVE THE IT SINCE I DON'T KNOW HOW MUCH GAS IT REALLY HAS. THE INFO BUTTON TELLS ME HOW MANY MILES I HAVE TO THE GALLON BUT HOW SURE IS THAT INFORMATION IS IF THE "SERVICE ENGINE SOON" IS ON. I REACHED ONLINE TO FIND I AM NOT THE ONLY PERSON WITH THE SAME ISSUE WITH THIS VEHICLE. COME TO FIND THE REPAIR IS PRICEY. THIS SHOULD BE A RECALL!!!!! NO ONE IS SAFE WHILE DRIVE A VEHICLE THAT SHOWS FALSE INFORMATION ON THE DASHBOARD. *TR

NHTSA ID
10497759
Incident
Feb 10, 2013
Fuel system
Filed Jul 14, 2012

THERE IS A DEFECT IN THE FUEL GAUGE INDICATOR. IT WILL RANDOMLY DROP FROM THE TRUE FUEL LEVEL TO ZERO FUEL. AFTER SOME VARIABLE TIME PERIOD IT WILL AGAIN GO FROM ZERO FUEL TO THAT ACTUAL FUEL LEVEL. THIS IS A SAFETY HAZARD BECAUSE IT CONFUSES THE DRIVER AS TO HOW MUCH FUEL THERE IS IN THE FUEL TANK AND MAY CAUSE THE DRIVER TO STOP THE CAR IN AN UNSAFE LOCATION. I HAVE HAD THIS CAR FOR SEVEN YEARS AND IT HAS PERSISTED ALL THESE YEARS. I CHECKED THE WEB AND OTHER FORD EXPLORER OWNERS HAVE THE SAME COMPLAINT. I BELIEVE THAT FORD SHOULD RECALL THESE CARS AND FIX THIS SAFETY HAZARD. *TR

NHTSA ID
10465650
Incident
Jan 2, 2006
Fuel system
Filed Feb 21, 2012

AFTER FILLING UP MY TANK, THE FUEL GAUGE DROPPED TO EMPTY, AND THE CHECK ENGINE SOON LIGHT CAME ON. ALSO THE SYSTEM THAT TELLS ME HOW MANY MILES TO EMPTY ONLY SHOWS DASHED INSTEAD OF AN ACTUAL NUMBER. I HAVE LOOKED ONLINE AND THIS SEEMS TO BE A COMMON AND PRICEY PROBLEM. THE DAY AFTER I FILLED UP, IT JUMPED TO HALF A TANK AND THEN BACK TO EMPTY. THIS IS VERY UNSAFE AND I DON'T KNOW IF THIS WILL CAUSE OTHER PROBLEMS. I HAVE ONLY HAD THE TRUCK 3 MONTHS. *TR

NHTSA ID
10448631
Incident
Feb 18, 2012
Mileage
140,000 mi
Fuel system
Filed Feb 17, 2012

THE FUEL GAUGE QUITS WORKING WHEN I FILL THE TANK. IT STARTS WORKING SOMETIMES AFTER A FEW DAYS. THE INFO CENTER THINKS I'M OUT OF GAS AND SENDS A WARNING. VERY ANNOYING. *TR

NHTSA ID
10448278
Incident
Feb 2, 2012
Mileage
73,000 mi
Fuel system
Filed Jan 13, 2012

TL* THE CONTACT OWNS A 2005 FORD EXPLORER. THE CONTACT STATED THAT THE CHECK ENGINE LIGHT WAS ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THEY ADVISED HIM THAT THE FUEL SENSOR BOARD FAILED AND NEEDED TO BE UPGRADED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS CONTACTED AND THEY OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS APPROXIMATELY 68,000 AND THE CURRENT MILEAGE WAS APPROXIMATELY 91,400.

NHTSA ID
10443673
Incident
Jan 7, 2010
Mileage
68,000 mi
EngineFuel system
Filed Aug 2, 2011

GAS CAP LIGHT COMES ON TRIGGERING THE CHECK ENGINE LIGHT. *KB

NHTSA ID
10416647
Incident
Feb 27, 2011
Mileage
70,000 mi
Driver assistanceEngineFuel system
Filed Jul 15, 2011

WHILE DRIVING, WHEN I APPLIED THE BRAKES, THE CAR LURCHED AND MADE A NOISE. ABOUT 1 MINUTE AFTER THAT, A WARNING LIGHT THAT STATED "ENGINE FAIL SAFE MODE" AND A LITTLE WRENCH SHOWED UP ON THE LEFT OF THE INSTRUMENT PANEL. I WAS DRIVING HOME, AND THE CAR STARTED TO SPEED UP WITHOUT MY INCREASING THE SPEED USING THE GAS PEDAL. THE CAR CONTINUED TO LURCH OFF AND ON UNTIL I GOT HOME. I RESEARCHED THIS PROBLEM ON THE INTERNET AND IT SEEMED TO BE THE THROTTLE BODY ASSEMBLY THAT HAD FAILED. UPON TAKING IT TO THE MECHANIC, THAT IS EXACTLY WHAT IS WAS. THE CAR WAS DANGEROUS TO DRIVE, I COULD HAVE BEEN KILLED HAD THE CAR'S SPEED KEPT INCREASING. THE REPAIR WAS $1026.00.

NHTSA ID
10413050
Incident
Jul 12, 2011
Mileage
58,084 mi

Higher-selling and older vehicles accumulate more reports. Counts are not failure rates and are not directly comparable between vehicles that sold in very different numbers.

Other components reported on this vehicle

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Elsewhere on this vehicle

Data sources

Data on this page last refreshed .