NHTSA Complaint #10587299 — 2009 FORD FLEX

OUR 2009 FORD FLEX HAS SHUT OFF ON 4 OCCASIONS WHILE WE WERE DRIVING SINCE NOV. 2013 (11/29/2013, 12/18/2013, 12/28/2013, 4/15/2014). ON 3 OF THE 4 OCCASIONS WE WERE ON INTERSTATE HIGHWAYS (495 IN MA, 95 IN CT, 81 IN PA) WHICH WAS SCARY AND COULD HAVE BEEN DEADLY. ON 2 OF THE 4 SHUT DOWNS THE CAR WOULD NOT RESTART SO WE HAD TO BE TOWED. WE NOTICED THAT ONCE THE CAR WAS TAKEN OFF THE FLATBED, IT STARTED RIGHT UP. THAT TELLS ME THAT THE GAS MUST HAVE MOVED TO WHERE IT WAS NEEDED. ON EACH OCCURRENCE THE GAS GAUGE READ HALF A TANK OR JUST SLIGHTLY BELOW. THE CAR JUST SHUT OFF WHICH MADE IT DIFFICULT TO STEER. LUCKILY WE WERE ABLE TO COAST TO THE BREAKDOWN LANE AND WEREN'T IN SPEEDING, HEAVY TRAFFIC. ON 12/21/13 THE DEALERSHIP REPLACED THE THROTTLE BODY. ON 12/28/13 THE CAR SHUT DOWN AGAIN AND WAS TOWED TO THE DEALERSHIP. THE FUEL SENDER CONCERN WAS VERIFIED, FUEL LEVEL WAS INACCURATE, THE LEFT HAND FUEL SENDER WAS ERRATIC. THEY REMOVED THE FUEL TANK, REPLACED THE LEFT FUEL SENDER. ON 4/15/14 THE CAR SHUT DOWN AGAIN. THE DEALERSHIP FOUND THAT THE RIGHT SIDE OF THE GAS TANK WAS EMPTY WHILE THE LEFT SIDE WAS FULL. THE FUEL SENDER ASSEMBLIES WERE REMOVED AND THE RIGHT ONE WAS NOT READING PROPERLY. THE FUEL PUMP MODULE WAS ALSO REPLACED. WE DO NOT TRUST THIS CAR AND ARE AFRAID FOR THE NEXT OWNER WHEN WE TRADE IT IN OR SELL IT. IS THIS A DESIGN FLAW? *TR