NHTSA Complaint #10631145 — 2005 FORD F-150

THE VEHICLE BEGAN TO SMELL LIKE RAW FUEL, PARTICULARLY AT STOP SIGNS OR INTERSECTIONS. THE SMELL APPEARED TO BE COMING FROM THE ENGINE BAY. UPON DISASSEMBLY OF THE INTAKE COMPONENTS OF THE ENGINE TO EXPOSE THE FUEL INJECTION SYSTEM, IT WAS EVIDENT THAT THE FUEL RAIL HAD BEGUN LEAKING RAW FUEL INSIDE THE ENGINE BAY. THE FUEL RAIL DEVELOPED A SPECK OF CORROSION ABOUT 2-3MM IN DIAMETER ON THE TOP SURFACE OF THE RAIL. THE CORROSION EVIDENTLY PENETRATED THE ENTIRE RAIL AND BECAME A PINHOLE LEAK. RAW FUEL WAS SEEN LEAKING UP AND OUT OF THE PINHOLE. THIS HAPPENED ON THE PASSENGER SIDE FUEL RAIL, WHICH IS POSITIONED INCHES AWAY FROM THE HIGH VOLTAGE COIL PACK, AND ABOVE THE EXHAUST MANIFOLD AS WELL. CALLED FORD CUSTOMER SERVICE HOTLINE AND WAS TOLD THERE IS NO RECALL FOR IT, NO EXTENDED WARRANTY PROGRAM, NO ASSISTANCE WHATSOEVER. ORDERED A NEW FUEL RAIL THROUGH LOCAL FORD DEALER FOR $500 DOLLARS (4 TIMES WHAT A TYPICAL FUEL RAIL COSTS); PART HAS NOT BEEN SHIPPED, DEALER UNSURE IF FORD HAS ANY IN STOCK OR IS EVEN MAKING THE PART. TRUCK HAS BEEN INOPERABLE FOR OVER A WEEK WITH NO WAY TO FIX IT. *TR