NHTSA Complaint #11363135 — 2011 FORD EXPLORER

AS A REPAIR SHOP OWNER, THE VEHICLE OWNER STATED THAT THERE WAS A STRONG FUEL ODOR AFTER FILLING THE FUEL TANK. I NOTICED FUEL STAINS FROM THE TOP OF THE TANK SO I REMOVED THE TANK AND FOUND FUEL LEAKING FROM THE FUEL PUMP MODULE. I FOUND THE STEEL LOCK RING RETAINING THE MODULE TO THE PLASTIC FUEL TANK HAD RUSTED AND THE RESULTING RUST 'BLOOM' HAD CRUSHED THE PLASTIC FLANGE CAUSING THE FUEL LEAK. I HAVE NOTICED THIS ON ANOTHER CAR ( 2007 DODGE GRAND CARAVAN, VIN [XXX]) JUST LAST WEEK WITH THE SAME ISSUE. AFTER SHARING THE PICTURES WITH A DIAGNOSTIC DISCUSSION GROUP, OTHERS HAVE SEEN THIS AROUND THE COUNTRY AND CANADA, ESPECIALLY IN THE "RUST BELT" STATES. THIS ISSUE SEEMS TO APPLY TO ANY FUEL SYSTEM WITH A PLASTIC FUEL PUMP MODULE AND A STEEL LOCK RING IN A RUST PRONE AREA. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR