2003 Ford F-150 Fuel system Problems

I purchased this F150 in November, 2023. The only code shown was a lean code, P0171. I removed the bed first to begin my inspection. Upon removing the original fuel tank, I discovered a gash in the top of the tank,about 1/8" wide by 3" long. It should have set a code like a missing gas cap would, but there was none. The gash appeared to be several years old due to the rust pitting. I believe the gash was a result of the cross member rubbing against the tank. The previous owner did not mention the defect. Fuel would have spilled out if the tank was completely filled. I did not find any service alerts for this though they may exist. The truck currently has 225k miles.

NHTSA ID

11566652

Incident

Jan 20, 2024

The contact owns a 2003 Ford F-150. The contact received notification of NHTSA Campaign Number: 11V385000 (Fuel System, Gasoline) however, the part to do the recall repair was unavailable. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had not experienced a failure. Parts distribution disconnect.

NHTSA ID

11491023

Incident

Jul 29, 2011

FUEL TANK SEPARATED FROM VEHICLE WHILE DRIVING ON HIGHWAY, RESULTING IN FUEL SPILL.

NHTSA ID

11383619

Incident

Dec 15, 2020

Mileage

258,000 mi

TL* THE CONTACT OWNS A 2003 FORD F-150. THE CONTACT STATED THAT THE CHECK ENGINE WARNING LIGHT HAD BEEN ILLUMINATED SINCE THE DAY OF PURCHASE. THE CONTACT ALSO STATED THAT WHILE THE VEHICLE WAS PARKED IN THE CAR PORT THE VEHICLE SUDDENLY CAUGHT ON FIRE. THE FIRE DEPARTMENT CAME AND PUT OUT THE FIRE. A FIRE DEPARTMENT REPORT WAS MADE. THE VEHICLE WAS DEEMED TOTALED AS WELL AS DAMAGED THE CONTACT'S RESIDENCE. THERE WERE NO INJURIES. THE CONTACT CONTACTED A CERTIFIED MECHANIC WHO INFORMED THEM OF A RECALL FOR THE YEAR/MAKE/MODEL, NHTSA CAMPAIGN NUMBER: 06E056000 (FUEL SYSTEM, GASOLINE). THE CONTACT STATED THE VIN HAD NOT SHOWN TO BE INCLUDED IN THE RECALL. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 203,000. *BF *DL

NHTSA ID

11327230

Incident

Apr 3, 2020

Mileage

203,000 mi

TL* THE CONTACT OWNS A 2003 FORD F-150. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 11V385000 (FUEL SYSTEM, GASOLINE). THE DEALER (LYNCH FORD CHEVROLET INC, 410 US-30, MT VERNON, IA 52314, 319-895-8500) WAS CONTACTED AND CONFIRMED THAT PARTS FOR THE RECALL REMEDY WERE NOT AVAILABLE. THE MANUFACTURER WAS NOT CONTACTED. THE CONTACT HAD NOT EXPERIENCED A FAILURE. PARTS DISTRIBUTION DISCONNECT.

NHTSA ID

11127941

Incident

Sep 6, 2018

I DROVE THE TRUCK ABOUT 90 MILES SUNDAY JULY 29. PARKED THE TRUCK IN FRONT OF MY HOME WENT INSIDE AND ABOUT 10 MINUTES LATER HEARD AN EXPLOSION. WENT OUT FRONT AND FOUND MY TRUCK ENGINE COMPARTMENT FULLY ENGULFED IN FLAMES. FIRE WAS SO HOT IT MELTED ENGINEER PARTS AND THE HOOD. I HAD CHECKED THE OIL, COOLANT AND TRANS PRIOR TO MAKING THE TRIP. THERE WERE NO LEAKS OF ANY TYPE. HAVE NEVER HAD ANY ISSUES WITH FULE OR OIL LEAKS.

NHTSA ID

11115093

Incident

Jul 29, 2018

Mileage

180,000 mi

GAS TANK IS LEAKING. JUST READ THERE WAS A RECALL ON IT

NHTSA ID

11084872

Incident

Apr 2, 2018

IN MARCH OF 2014, MY FUEL TANK STRAPS BROKE DUE TO EXCESSIVE CORROSION AND MY FUEL TANK FELL TO THE ROAD WHILE I WAS DRIVING. I PAID TO HAVE IT REPAIRED THAT SAME MONTH BUT I RECENTLY LEARNED THAT THIS PROBLEM WAS IN A FORD RECALL, CAMPAIGN NUMBER 11S21. I TOOK THE BILL TO A LOCAL FORD DEALERSHIP, PER THE FORD RECALL INSTRUCTIONS, BUT THEY DENIED MY CLAIM BECAUSE I NO LONGER OWN THE VEHICLE; IT WAS TOTALED IN 2015

NHTSA ID

11015784

Incident

Mar 26, 2014

Mileage

90,000 mi

THE FUEL TANK STRAP HAS BROKEN DUE TO CORROSION. THERE IS AN ACTIVE RECALL ON THIS ISSUE FOR SIMILAR VEHICLES FROM FORD, BUT FORD STATED MINE IS NOT INCLUDED. THIS IS VERY DANGEROUS.

NHTSA ID

10948699

Incident

Jan 17, 2017

Mileage

130,000 mi

TRANS WENT OUT A MONTH AFTER INTAKE CRACK HAD TO BE REPLACE ALMOST $1,650 TOGETHER ALSO BALL JOINTS AND TIEROD ENDS NO GOOD SHOCK NO GOOD BRAKE ARE FALLING AND REAR END IS GRINDING THIS TRUCK SHOULD HAVE NEVER BEEN SOLD HELP AND THERE'S "MORE".

NHTSA ID

10936142

Incident

Nov 7, 2016

TL* THE CONTACT OWNS A 2003 FORD F-150. THE CONTACT STATED THAT THE FUEL TANK STRAP FRACTURED AND CAUSED THE FUEL TANK TO SEPARATE FROM THE VEHICLE. THE FUEL TANK WAS PUNCTURED. THE CONTACT STATED THAT THERE WAS EVIDENCE OF A FUEL LEAK UNDERNEATH THE VEHICLE. THE CONTACT WAS CONCERNED THAT THE PUNCTURED FUEL TANK WAS A FIRE HAZARD. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE VEHICLE WAS INCLUDED IN NHTSA CAMPAIGN NUMBER: 11V385000 (FUEL SYSTEM, GASOLINE). THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 120,000.

NHTSA ID

10923900

Incident

Oct 25, 2016

Mileage

120,000 mi

TL* THE CONTACT OWNS A 2003 FORD F-150. WHILE THE VEHICLE WAS STATIONARY, FUEL LEAKED ONTO THE GROUND. IN ADDITION, THE STRAPS THAT HELD UP THE FUEL TANK HAD EXCESSIVE RUST. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE ISSUE. THE FAILURE MILEAGE WAS 111,000.

NHTSA ID

10916620

Incident

Oct 15, 2016

Mileage

111,000 mi

TL* THE CONTACT OWNS A 2003 FORD F-150. THE CONTACT STATED THAT THE FUEL TANK FAILED. WHILE DRIVING 10 MPH, THE VEHICLE EMITTED A POPPING NOISE. THE CONTACT WAS ABLE TO COAST ONTO THE SHOULDER, INSPECTED THE VEHICLE, AND FOUND THAT THE FUEL TANK SEPARATED FROM THE STRAP DUE TO CORROSION. THE VEHICLE WAS TOWED TO THE CONTACT'S HOME. THE DEALER STATED THAT THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 11V385000 (FUEL SYSTEM, GASOLINE). THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED. THE FAILURE MILEAGE WAS 100,000.

NHTSA ID

10885777

Incident

Jul 17, 2016

Mileage

100,000 mi

TL* THE CONTACT OWNS A 2003 FORD F-150. THE CONTACT STATED THAT WHILE DRIVING AT AN UNKNOWN SPEED, THE FUEL TANK STRAP FRACTURED AND THE FUEL TANK DROP TO THE GROUND. THE VEHICLE WAS TAKEN TO THE DEALER. THE TECHNICIAN CONFIRMED THAT BOTH FUEL TANK STRAPS FRACTURED DUE TO CORROSION AND AS A RESULT, THE FUEL TANK NEEDED TO BE REPLACED. THE TECHNICIAN MADE THE CONTACT AWARE THAT THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 11V385000 (FUEL SYSTEM, GASOLINE). THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 160,000.

NHTSA ID

10851897

Incident

Mar 28, 2016

Mileage

160,000 mi

WHILE DRIVING MY TRUCK WITH MY WIFE & SON, WE HEARD A LOUD POP, LIKE A GUN SHOT, THEN MY TRUCK STARTED TO RUN REAL ROUGH, I FOUND A COIL, & A SPARK PLUG HAD BEEN BLOWN OUT OF THE ENGINE, BECAUSE OF THE FUEL BUILD UP & THE SPARK FROM THE TRUCK STILL RUNNING WE ARE LUCKY THAT THE TRUCK DID NOT CATCH FIRE.

NHTSA ID

10730766

Incident

Jun 21, 2015

Mileage

222,050 mi

GAS TANK STRAPS CORRODED/BROKE CAUSING THE TANK TO DROP AND LEAK. EXCESSIVE RUST AT BOTTOMS OF ALL FOUR DOORS. *TR

NHTSA ID

10672425

Incident

Jan 14, 2015

Mileage

50,000 mi

ANOTHER CRACKED PASSENGER SIDE MANIFOLD ON REGULARLY SERVICED VEHICLE. FORD MOTOR COMPANY SHOULD ISSUE RECALL OR PROVIDE "GOODWILL" BASED ON THE NUMBER OF FAILED COMPONENTS BEING REPORTED BY FORD OWNERS. *TR

NHTSA ID

10660425

Incident

Nov 20, 2014

Mileage

120,000 mi

TL* THE CONTACT OWNS A 2003 FORD F-150. WHILE INSPECTING THE VEHICLE, IT WAS DISCOVERED THAT THE FUEL TANK STRAPS WERE RUSTED AND CORRODED. THE DEALER STATED THAT THE STRAPS NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE CONTACT WAS INFORMED THAT THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 11V385000 (FUEL SYSTEM, GASOLINE). THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 105,000.

NHTSA ID

10650736

Incident

Oct 27, 2014

Mileage

105,000 mi

MY 2003, FORD F-150 BLEW A SPARK PLUG FOR THE FOURTH TIME YESTERDAY. EACH TIME A DIFFERENT PLUG. I WAS HEADING TO CHURCH AND "POP". WE WERE JUST GETTING ON THE ON RAMP WHEN IT HAPPEN. FOUR TIME NOW AND EACH TIME I HAVE TO PAY TO GET IT FIXED. RIGHT NOW I CAN'T AFFORD TO FIX IT AND IT'S SITTING IN MY YARD... *TR

NHTSA ID

10631545

Incident

Sep 7, 2014

Mileage

160,000 mi

TL* THE CONTACT OWNS A 2003 FORD F-150. THE CONTACT STATED THAT THE VEHICLE WAS PARKED IN A RESIDENTIAL GARAGE WHEN IT WAS NOTICED THAT THERE WAS A SUBSTANTIAL GASOLINE FUEL LEAK. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC WHERE THE FUEL TANK WAS REPLACED DUE TO EXCESSIVE CORROSION NEAR THE PASSENGER'S SIDE FUEL TANK STRAPS. THE MANUFACTURER WAS NOTIFIED OF THE PROBLEM AND ADVISED THE CONTACT THAT THERE WERE NO RECALLS FOR THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 113,000.

NHTSA ID

10573448

Incident

Mar 12, 2014

Mileage

113,000 mi

WHILE TRAVELING SOUTH BOUND ON INTERSTATE 81 AT CHRISTIANSBURG VA. MY GAS TANK FELL OFF OF THE VEHICLE DUE TO DEFECTIVE STRAPS RUSTING INTO AND LETTING IT FALL CAUSING GASOLINE TO LEAK ON ROADWAY AND ALMOST CAUSING A FIRE. THE GAS TANK STRUCK THE ROADWAY AND THE GRINDING CAUSED THE TANK TO LEAK AND THE SPILLAGE. I HAD TO HAVE THE VEHICLE TOWED TO A LOCAL REPAIR SHOP AND HAVE PURCHASED A USED GAS TANK AND ORDERED NEW STRAPS. I HAVE WRITTEN FORD AN E MAIL, ASKING THEM TO HELP WITH THIS PROBLEM. *TR

NHTSA ID

10565025

Incident

Feb 19, 2014

Mileage

116,000 mi

TL* THE CONTACT OWNS A 2003 FORD F-150. THE CONTACT STATED WHILE HAVING ROUTINE MAINTENANCE PERFORMED BY AN INDEPENDENT MECHANIC HE WAS INFORMED THAT THE GASOLINE TANK WAS LEAKING. THE DEALER NOTIFIED THE CONTACT OF NHTSA RECALL CAMPAIGN NUMBER: 11V385000 (FUEL SYSTEM, GASOLINE). THE VEHICLE WAS TAKEN TO A DEALER FOR REPAIR BUT WAS INFORMED THAT THEY WOULD ONLY REPAIR THE VEHICLE IF THE GASOLINE TANK WAS REPLACED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 200,000.

NHTSA ID

10543248

Incident

Sep 10, 2013

Mileage

200,000 mi

USED 2003 FORD F150 I ORDERED A $100. NY INSPECTION, THE SERVICE ADVISOR INFORMED ME THAT THIS TRUCK HAD A PROBLEM, THE FUEL TANK STRAPS RECALL HIS RECORDS SHOWED ON PAPER THAT IT WAS DONE, BUT UPON A PHYSICAL INSPECTION IT WAS NOT DONE, ONLY SOME MAKE SHIFT WIRES TO HOLD UP THE GAS TANK THE SERVICE ADVISOR GAVE THE WIRES TO ME TO SHOW YOU HE CONTACTED THE FORD DEALER IN MASSACHUSETTS THEY SAID IT WAS NOT THEIR RESPONSIBILITY SINCE THEY HAD CLOSED THE CASE MY SERVICE ADVISOR THEN INFORMED ME THAT HE WOULD CALL 'FORD SPECIAL ASSISTANCE HE SAID THEY DENIED THE ASSISTANCE AFTER THE CALL HE INFORMED THAT IT WOULD BE MY RESPONSIBILITY TO PAY FOR NEW STRAPS AND THE INSTALLATION LABOR AND TAXES. IT IS MY UNDERSTANDING THAT THE VEHICLE MANUFACTURE IS RESPONSIBLE TO CARE FOR THIS PROBLEM AND THROUGH THEIR DEALERS. ESPECIALLY GAS TANK STRAPS!! AND ALSO IT SEEMS LOGICAL THAT THE RECALL IS TO THE VEHICLE, NOT THE CUSTOMER. IN THIS CASE THEIR RECORDS ARE SAYING THAT IT WAS DONE AND THEN FINDING THAT IT IS NOT. THE SERVICE ADVISOR MADE HIS ATTEMPTS TO GET IT DONE THROUGH FORD, BUT COULD NOT. THIS IS MOST REPREHENSIBLE, AND CROOKED ON SOMEONE PART, THE OTHER DEALER AND NOW FORD. THE OTHER DEALER DID GET PAID FOR SOMETHING THEY DID NOT DO, AND NOW FORD WILL NOT TAKE CARE OF THIS. THE ADVISOR GAVE ME THE CUSTOMER SERVICE # TO 'FOMOCO. THE FOMOCO AGENT THEN TOLD ME THAT, IT WAS BETWEEN THE DEALERSHIPS AND HE ASSURED ME THAT THEY WOULD HANDLE THE MATTER. WHEN I CALLED BACK THE SERVICE MANAGER HE SAID MY HANDS ARE TIED, THE OTHER DEALER WOULD NOT REOPEN THE CASE AND FORD SPECIAL ASSISTANCE WOULD NOT BACK ANY THING UP. IF I WANTED TO PASS THE EMISSION AND SAFETY INSPECTION AND REGISTER MY TRUCK I WOULD HAVE TO PAY THE BILL I HAVE BEEN GIVEN THE RUN-AROUND THANK YOU *TR

NHTSA ID

10487916

Incident

Dec 6, 2012

Mileage

183,043 mi

MY 2003 F150 HAD THE STRAPS HOLDING THE GAS TANK SNAPPED WHILE TRAVELING DOWN THE INTERSTATE AT 65 MPH, I COULD SEE FLAMES ON THE ROAD FROM THE FUEL LEAKING WHEN THE TANK HIT THE HIGHWAY. ONCE I STOPPED THE TRUCK, I FOUND THE GAS TANK HAD FALLEN OFF AND WAS DRAGGING THE GROUND LEAKING FUEL EVERYWHERE, I HAD 20 GALLONS OF FUEL LEAK OUT SO I HAD TO CALL THE BRISTOL, VA FIRE DEPT. TO COME CLEAN UP THE FUEL SPILL, THERE WAS NO DAMAGE TO THE TRUCK OTHER THAN THE FUEL TANK AND THE STRAPS THAT I KNOW OF NEEDING TO BE REPLACED. THE LOCAL FORD DEALER TELLS ME THAT FORD HAS A RECALL ON THIS IN AREAS OF THE COUNTRY, BUT NOT IN VIRGINIA. THE FORD RECALL SAYS IT IS ONLY IN AREAS THAT USE ROAD SALE (HIGH CORROSION) AREAS SUCH AS KENTUCKY AND WEST VIRGINIA, I LIVE IN VIRGINIA NEAR THE KENTUCKY BOARDER ( WITHIN 20 MILES) I FEEL THE RECALL NEEDS TO BE EXPANDED TO VIRGINIA THE FORD DEALER TOLD ME THEY HAVE SEEN OTHER ISSUES LIKE THIS IN THEIR SHOP. THIS RECALL NEEDS TO BE EXPANDED QUICKLY I WAS BLESSED THAT THE SPARKS FROM THE TANK DRAGGING THE GROUND DID NOT RESULT IN AN EXPLOSION AND FIRE THAT COULD HAVE LED TO SERIOUS INJURY OR POSSIBLY MY DEATH OR EVEN SOMEONE ELSE BEING INJURED THIS IS A HUGE ISSUE THAT NEEDS TO BE ADDRESSED. *JB

NHTSA ID

10461730

Incident

Jun 13, 2012

Mileage

189,000 mi

TL* THE CONTACT OWNS A 2003 FORD F-150. THE CONTACT STATED THAT THE VEHICLE WAS INCLUDED IN THE RECALL ASSOCIATED WITH NHTSA CAMPAIGN ID NUMBER 11V385000 (FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:MOUNTING). THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER AND THE CONTACT WAS ADVISED THAT THE FUEL TANK WAS ALSO CORRODED, BUT THAT FAILURE WAS NOT ADDRESSED IN THE RECALL. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 57,000.

NHTSA ID

10449596

Incident

Feb 28, 2012

Mileage

57,000 mi