NHTSA Complaint #11419723 — 2002 HONDA ODYSSEY

06/04/2021 2002 Honda Odyssey - Aftermarket Fuel Pump Lock Ring - Multiple Failures Safety Issue = Gasoline leaking out of the tank onto the ground. Starting in 2019, three aftermarket fuel pump lock rings have failed on one 2002 Honda Odyssey. The lock rings were all made of plastic. The OEM Honda lock ring was also made of plastic and after 17 years did not fail, but was replaced when a new fuel pump was installed. A DELPHI model FG0956 fuel pump had two lock ring failures. The third lock ring failure was on a AIRTEX model E8642M fuel pump. The torque spec per Honda for the fuel pump lock ring is a hefty 69 FT LBS or 93 NM. An SK click type torque wrench model 73100 was used on the installs, as was a fuel tank lock ring tool LISLE model 63000. All the lock rings were at first hand tightened to prevent cross threading before using the torque wrench. The SK torque wrench used has never been known to over torque bolts. The third lock ring for AIRTEX was torqued to about 60 FT LBS due to the prior failures. No warning lights or messages appeared when the lock ring fails. All failed within one year of install. Failure detected by noticing the smell of gasoline, especially outside the vehicle and sometimes inside the vehicle. Each of the failed lock rings split, and then gasoline starts leaking out of the top of the tank at the fuel pump and onto the ground. The fuel pump will start to rise above the tank due to it being spring loaded and the lock ring failing. The problem is most noticeable after filling the fuel tank, and when the vehicle is exposed to high outside air temperatures. If you look under the vehicle, a puddle of gasoline on the ground is sometimes visible just below the fuel pump. If the failure is not yet severe enough, you will not see a puddle but may still smell gasoline. A local auto parts store recommended purchasing an OEM Honda lock ring due to the aftermarket failures and the hefty Honda torque spec of 69 FT LBS on a plastic ring.