1996 Ford F-150 Fuel system Problems

The contact owns a 1996 Ford F-150. The contact stated while driving 45 MPH, the vehicle started to shutoff and restart independently. The check engine warning light was illuminated. The vehicle was diagnosed by an independent mechanic. The mechanic informed the contact that the rear tank’s fuel pump needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and confirmed that there was no open recall associated with the VIN for the failure. The failure mileage was approximately 130,000. The contact stated there is an issue with the front fuel tank feeding fuel into the rear tank when the rear tank pump is not operational and having to switch the fuel supply over to the front tank. When the rear tank is full from the front tank feed, it spills over out of the rear tank fill spout, and runs out on the ground.

NHTSA ID

11540729

Incident

Apr 15, 2023

Mileage

130,000 mi

The front fuel tank is overflowing when I run the vehicle with the rear tank. The return fuel is always to the front tank causing it to overflow its a hazardous situation.

NHTSA ID

11473139

Incident

Jul 9, 2022

FUEL FROM REAR TANK FILLS FRONT TANK.IT CAN OVERFLOW CAUSING A FIRE.

NHTSA ID

11362648

Incident

Sep 1, 2020

Mileage

111,500 mi

FUEL FLOWS OUT THE FRONT TANK WHEN USING THE REAR TANK AND THE FRONT ON IS FULL !! FOUND THIS WHEN PARKED IN MY GARAGE .

NHTSA ID

10938604

Incident

Dec 15, 2016

Mileage

88,000 mi

FUEL FROM THE FRONT TANK IS OVERFLOWING FUEL INTO THE REAR FUEL TANK AND VICE VERSA. THIS HAS BEEN HAPPENING FOR YEARS BUT NO ONE SEEMS TO KNOW HOW TO REPAIR OR WHAT IS CAUSING THE ISSUE.

NHTSA ID

10811833

Incident

Dec 1, 2004

FUEL KEEPS LEAKING FROM SECOND TANK SOMEWHERE TOWARDS THE OPENING.BEEN LIKE THIS SINCE THE DATE I HAVE REPORTED TILL NOW BUT NEVER THOUGHT MUCH ABOUT IT UNTIL REVIEWING CASE NHTSA ID NUMBER: [XXX] AND NHTSA REF # 10587059 INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ID

10683764

Incident

Jan 10, 2009

Mileage

120,000 mi

TL* THE CONTACT OWNS A 1996 FORD F-150. THE CONTACT STATED THAT THE VEHICLE WAS EQUIPPED WITH A DUAL FUEL TANK AND WHILE DRIVING VARIOUS SPEEDS, A STRONG ODOR OF GASOLINE EMITTED INSIDE AND OUTSIDE OF THE VEHICLE. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER, WHO STATED THAT THE FUEL RETURN CHECK VALVE WOULD NEED TO BE REPLACED BECAUSE THE FUEL FROM THE REAR FUEL TANK OVERFLOWED INTO THE SECOND FUEL TANK. IN ADDITION, FUEL HAD SEEPED OUT OF THE FUEL TANK CAP. THE VEHICLE WAS NOT REPAIRED. THERE WAS A RECALL ISSUED FOR 1990-1993 F-SERIES MODEL VEHICLES UNDER NHTSA CAMPAIGN ID NUMBER: 01I008000 (FUEL SYSTEM, GASOLINE) BUT NOT FOR THE 1996 MODEL YEARS. THE MANUFACTURER WAS NOTIFIED OF THE DEFECT. THE APPROXIMATE FAILURE MILEAGE WAS 120,000. UPDATED 06/30/14 MA UPDATED 07/2/2014 *JS

NHTSA ID

10587059

Incident

Aug 8, 2007

Mileage

120,000 mi

TL* THE CONTACT OWNS A 1996 FORD F-150. THE CONTACT NOTICED FUEL LEAKING FROM THE FILLER CAP. AFTER INSPECTING THE VEHICLE, THE CONTACT NOTICED THAT THE FUEL FROM THE REAR FUEL TANK WAS SPILLING INTO THE FRONT FUEL TANK, CAUSING IT TO OVERFLOW AND LEAK. THE VEHICLE WAS NOT TAKEN TO THE DEALER FOR DIAGNOSTIC. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 105,000.

NHTSA ID

10463596

Incident

Jun 15, 2012

Mileage

105,000 mi

TL* THE CONTACT OWNS A 1996 FORD F-150. THE CONTACT STATED WHILE DRIVING APPROXIMATELY 20 MPH THE FUEL TANK DETACHED FROM THE VEHICLE. APPROXIMATELY 3 GALLONS OF FUEL SPILLED OUT OF THE VEHICLE. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC WHO ADVISED HIM THAT BOTH STRAPS WERE SEVERELY COVERED WITH RUST AND NEEDED TO BE REPLACED ALONG WITH THE FUEL TANK. BOTH STRAPS AND THE FUEL TANK WERE REPAIRED. THE MANUFACTURER WAS CONTACTED REGARDING THE FAILURE AND STATED HIS VIN WAS NOT INCLUDED IN ANY RECALLS. THE FAILURE MILEAGE WAS APPROXIMATELY 122,700.

NHTSA ID

10430047

Incident

Oct 6, 2011

Mileage

122,700 mi

PRIMARY FUEL TANK STRAPS BROKEN, TANK RESTING ON SKID PLATE. SECONDARY FUEL TANK STRAPS CORRODING. *TR

NHTSA ID

10428117

Incident

Jul 1, 2008

Mileage

145,000 mi

TL* THE CONTACT OWNS A 1998 FORD F-150. WHILE THE VEHICLE WAS PARKED THE CONTACT NOTICED FUEL LEAKING FROM THE FUEL TANK. THERE WAS A NHTSA RECALL CAMPAIGN ID NUMBER: 98V161000 (FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY) THAT MAY BE RELATED TO THE FAILURE. THE DEALER WAS MADE AWARE OF THE FAILURE AND STATED THE VIN WAS NOT INCLUDED IN THE RECALL. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 100,000.

NHTSA ID

10425158

Incident

Aug 13, 2011

Mileage

100,000 mi

TL* THE CONTACT OWNS A 1996 FORD F150. THE CONTACT STATED THAT THE FRONT FUEL TANK STRAP WAS CORRODED AND CAUSED A LEAK IN THE FUEL TANK. HE TOOK THE VEHICLE TO A LOCAL MECHANIC WHO REPAIRED THE STRAP BUT DID NOT REMEDY THE ISSUE WITH THE FUEL LEAK. THE CONTACT THEN SWITCHED TO USING THE REAR FUEL TANK, IN WHICH HE SOON DISCOVERED THAT THE THERE WAS ALSO A LEAK COMING FROM THE REAR TANK. THE MANUFACTURER WAS CONTACT WHO STATED THAT THERE WERE NO RECALLS FOR THE FAILURE AND OFFERED NO FURTHER ASSISTANCE. THE CONTACT PROCEEDED TO FILE A CLAIM WITH THE MANUFACTURER. THE FAILURE MILEAGE WAS 92,000.

NHTSA ID

10420038

Incident

Aug 18, 2011

Mileage

92,000 mi

TL*THE CONTACT OWNS A 1996 FORD F150. THE CONTACT STATED THAT FUEL WAS FLOWING FROM THE REAR FUEL PUMP AND INTO THE FRONT FUEL PUMP, CAUSING AN OVERFLOW AND ABNORMAL LEAKAGE. THE MANUFACTURER WAS CONTACTED AND THEY ADVISED THE CONTACT THAT SOMEONE WOULD RETURN HIS CALL BUT TO NO AVAIL. THE VEHICLE WAS TAKEN TO THE DEALER WHO PERFORMED A DIAGNOSTIC THAT LOCATED THE FAILURE AT THE FRONT FUEL PUMP CHECK VALVE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 80,000 AND THE CURRENT MILEAGE WAS 83,553.

NHTSA ID

10396991

Incident

Feb 1, 2011

Mileage

80,000 mi

TL*THE CONTACT OWNS 1996 FORD F150. THE CONTACT ATTEMPTED TO START THE VEHICLE AND IT WOULD NOT START; HOWEVER, AFTER SWITCHING TO THE REAR FUEL TANK THE VEHICLE STARTED. THE FRONT FUEL TANK HAD APPROXIMATELY A HALF TANK OF FUEL IN IT AT THE TIME. THE CONTACT NOTICED THAT THE FUEL WAS LEAKING IN THE FRONT FUEL TANK. THE FUEL WAS OVERFLOWING FROM THE BACK TO THE FRONT FUEL TANK CAUSING A LEAK AND A FUEL ODOR. THE VEHICLE WAS NOT TAKEN TO THE DEALER FOR DIAGNOSTIC TESTING OR TO BE REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 160,000.

NHTSA ID

10386958

Incident

Feb 20, 2011

Mileage

160,000 mi

I OWN A 1996 FORD F150 WITH DUAL TANKS. I HAVE A PROBLEM WITH THE BACK FUEL TANK TRANSFERRING GAS TO THE FRONT TANK. IF UNNOTICED THIS WILL CAUSE GAS TO OVERFLOW ONTO THE GROUND CAUSING A REAL SAFETY AND POLLUTION HAZARD. I CALLED FORD AND THEY SAID THAT THERE WASN'T ANY RECALL FOR THIS PROBLEM ON MY VIN. WELL EVEN IF THERE ISN'T A RECALL FOR THIS PROBLEM OR NOT IT IS STILL A PROBLEM AND THERE WAS A RECALL FOR THIS PROBLEM ON THE 1990 TP 1993 F150 SO I'M FIGURING THAT THEY STILL HAVE THE PROBLEM ON MY VEHICLE ALSO. *TR

NHTSA ID

10352940

Incident

Jul 22, 2010

Mileage

109,000 mi

TL*THE CONTACT OWNS A 1996 FORD F-150. WHENEVER THE CONTACT WOULD ATTEMPT TO STOP THE VEHICLE, IT WOULD TURN OFF AND FAIL TO RESTART. THE VEHICLE WAS TAKEN TO THE DEALER AND THEY STATED THAT THE FUEL PRESSURE REGULATOR NEEDED TO BE REPLACED. THE CONTACT ALSO NOTICED THAT THE SECOND FUEL TANK WAS TRANSFERRING FUEL TO THE FIRST FUEL TANK. THERE WERE NO WARNINGS PRIOR TO THE FAILURES. THE CURRENT AND FAILURE MILEAGES WERE 104,000.

NHTSA ID

10275607

Incident

May 14, 2009

Mileage

104,000 mi

TL*THE CONTACT OWNS A 1996 FORD F-150. THE CONTACT STATED THAT FUEL BEGAN TO LEAK FROM THE VEHICLE WHILE IT WAS PARKED. HE OPENED THE FUEL CAP AND GAS POURED OUT. THE DEALER STATED THAT A REGULATOR OR A FUEL PUMP NEEDED TO BE REPLACED. THE MANUFACTURER STATED THAT THERE IS A RECALL, BUT THE VEHICLE IS NOT INCLUDED. THE CURRENT AND FAILURE MILEAGES WERE 102,000.

NHTSA ID

10196565

Incident

Jul 15, 2007

Mileage

102,000 mi

THE VEHICLE HAS 2 FUEL TANKS. WHILE DRIVING, GASOLINE FLOWS FROM ONE TANK TO THE SECOND TANK, CAUSING THE SECOND TANK TO OVERFILL. WHEN OPENING THE LID TO THE SECOND TANK, PRESSURE CAUSED BY EXCESSIVE AMOUNT OF GASOLINE CAUSES GASOLINE TO SPEW FROM THE SPOUT ONTO OPERATOR AND ONTO THE GROUND. *JB

NHTSA ID

10183538

Incident

Feb 22, 2007

Mileage

90,000 mi

DT*: THE CONTACT STATED WHILE THE VEHICLE WAS STOPPED TO REFUEL, THE GAS CAP WAS REMOVED AND GASOLINE BLEW OUT OF THE FILLER PIPE. THERE WAS A RECALL #93V125000 FOR A SIMILAR PROBLEM WITH 1990-1993 FORD F-150 MODELS THAT CAUSED FUEL OVERFLOW DUE TO A MALFUNCTION OF THE CHECK VALVE BETWEEN THE DUEL TANKS. THE CONTACT HAS CONTACTED THE SERVICE DEALER AND THE MANUFACTURER.

NHTSA ID

10164309

Incident

Jul 30, 2006

Mileage

105,000 mi

DT*: THE CONTACT STATED THE CHECK VALVE IN THE FUEL PUMP ASSEMBLY MALFUNCTIONED AND THE UNUSED FUEL TRANSFERRED FROM ONE TANK TO ANOTHER. NO SPILLAGE OCCURRED BECAUSE THE SECOND TANK WAS NOT OVERFILLED. THERE IS A NHTSA RECALL, # 93V125000, REGARDING THE FUEL SYSTEM ASSEMBLY. THE VEHICLE HAS THE SAME PROBLEMS AS INDICATED IN THE RECALL; HOWEVER IT IS NOT INCLUDED IN THE RECALL DUE TO THE VIN. THE VEHICLE HAS NOT BEEN INSPECTED.

NHTSA ID

10149039

Incident

Jan 30, 2006

Mileage

30,000 mi

FUEL TANKS. FILLED REAR TANK AND OPENED FRONT TANK TO FILL IT. WHEN I TOOK CAP OFF GAS SPLASHED OUT. THE FRONT TANK WAS OVER FULL. I TALKED TO A FORD MECHANIC AND HE TOLD ME THAT IT WAS A VALVE IN THE RETURN LINE THAT CAUSED THE FRONT TANK TO OVER FILL FROM THE REAR TANK. HE ALSO SAID THAT FORD DID REPAIR SOME TRUCKS ,BUT WASN'T DOING IT NOW. *JB

NHTSA ID

10145180

Incident

Nov 23, 2005

Mileage

207,000 mi

DT: THE CONTACT OWNS A 1996 FORD F150. THE CONTACT STATED THE VEHICLE HAS A DUEL GASOLINE TANK. WHEN THE BACK TANK IS SELECTED IT WILL PUMP GASOLINE TO THE ENGINE, BUT IT WILL ALSO PUMP GASOLINE INTO THE FRONT TANK AND PRESSURIZE THE GASOLINE, FORCING IT OUT OF THE FILLER NECK AND CAP. WHEN THE VEHICLE IS PARKED GASOLINE OVERFLOWS ONTO THE GROUND, AND WHEN DRIVING THE VEHICLE, THE GASOLINE SPILLS OUT ALONG THE HIGHWAY. WHEN THE CAP IS REMOVED FROM THE TANK, A LARGER AMOUNT OF GASOLINE WILL SPILL OUT, AND THE GASOLINE IS FILLED UP TO THE FILLER NECK. THE CONSUMER HAS TO WATCH THE AMOUNT OF GASOLINE THAT IS IN THE BACK TANK TO ENSURE THAT THE OVERFLOW WILL NOT OCCUR. THE SERVICE DEALER SAID THAT THE CHECK VALVE HAD TO BE REPLACED. THE CHECK VALVE PREVENTED THE GASOLINE FROM GOING FROM THE BACK TANK INTO THE FRONT TANK. THE MANUFACTURER SAID THEY WOULD NOT COVER THE COST FOR THE REPAIR.*AK UPDATED 01/04/06. *JB

NHTSA ID

10138652

Incident

Jul 1, 2005

Mileage

72,000 mi

NORMAL DRIVING. STOPPED TO REFUEL. UPON ATTEMPTING TO OPEN REAR GAS CAP PRESSURE BLEW CAP OFF AND LARGE AMOUNT FUEL ALL OVER ME AND THE SIDE OF THE TRUCK. *AK CONDITION NOT REPAIRED AS YET.

NHTSA ID

10116575

Incident

Apr 7, 2005

Mileage

104,751 mi

THE VEHICLE HAD DUAL GAS TANKS. THE FRONT TANK WAS LEAKING FUEL OUT OF THE CAP SINCE THE FUEL FROM THE BACK TANK WAS TRAVELING TO THE FRONT. *AK THE DEALER REPLACED THE FUEL PUMP. *BF *SC

NHTSA ID

10101252

Incident

Dec 1, 2000

Mileage

82,931 mi

DUAL GAS TANKS. GAS IS PRESSURIZED FROM REAR TANK TO THE FRONT TANK, CAUSING A FUEL TRANSFER TO THE FRONT TANK, FRONT TANK IS OVERFILLING, GAS IS UNDER PRESSURE, SPILLING FROM THE OVERFLOW. WHEN THE CAP IS REMOVED, GAS EXPLODES FROM THE FILLER NECK. *AK

NHTSA ID

10110560

Incident

Jan 5, 2005

Mileage

187,799 mi