NHTSA Complaint #11584273 — 2012 FORD TRANSIT CONNECT

1. The heat shielding around the exhaust system failed to protect the fuel tank from exhaust heat. Heat from the exhaust system melted holes in the fuel tank, causing fuel to leak from the tank. The parts are at the Ford dealer with the vehicle. 2. The fuel tank developed leaks when it melted, causing a risk of fire or explosion. 3. The dealer confirmed that the fuel tank melted and leaked due to heat from the exhaust system. In diagnosing the issue, they refilled the fuel tank and it continued to leak. 4. To my knowledge, the vehicle or components have not been inspected by the manufacturer, police, insurance representatives, or others. My insurance chose not to be involved since it does not fall under "comprehensive" coverage, as there was no theft, vandalism, storm, or animal damage. 5. The vehicle waring lamps did not indicate the melting of the fuel tank or the leak. I was not aware that there was damage to the fuel tank or a fuel leak at the time. The vehicle simply ceased to run and would not start. I was towed to a Ford dealership. A week later the dealership called to inform me that they had added fuel to the tank to diagnose the starting issue, but were still unable to start, and wanted to replace the fuel pump. I explained that the tank had been filled only about 80 miles before, so there was some issue. Another week later, the dealer informed me that when replacing the fuel pump they had found that the tank had been melted. This was when I was first aware of the issue with the fuel tank.