NHTSA Complaint #11707368 — 2006 FORD MUSTANG

This has happened since purchasing my personal 2006 Mustang GT new in 2006. I also see early S-197 Mustangs (2005—2007) in my shop that cannot be reliably refilled because fuel shoots out of the filler neck, splashes the operator, the side of the Mustang, and puddles on the ground. The defective On-board Refueling and Vapor Recovery (ORVR) system causes high internal fuel tank pressures that will also cause the filling station pump to cut off and prevent putting fuel in the tank. This creates a fire hazard as the spillage contacts the left hot tail pipe and muffler as well as a puddle of fuel that can be ignited by a spark, cigarette, etc. This problem is in direct violation of the Environmental Protection Agency emission standards that clearly state the operator is “expected to fill the fuel tank without spit back or spillage during the refueling event.” EPA emission regulations also require that service vents, also known as safety and vacuum relief valves, be installed in tanks to prevent excessive pressure or vacuum that can build up “due to tank filling or emptying.” The parts of the Ford ORVR system that contribute to the fuel tank pressure spikes and fuel spills include: 1.Poor fuel filler design. The filler pipe is narrow (5/8” to 3/4”) with a severe an S-bend before it reaches the tank. There is a spring-loaded plug at the top of tank built into the fill neck that closes the fill pipe until fuel pushes the plug down to open the fuel tank. 2.Poor fuel tank design. The saddle style tank has two sections that “saddle bag” over the drive shaft making the opening between the two tanks very narrow and at the top of the tank. 3.Insufficient tank venting system. The capacity of this vent system is not sufficient to vent the fuel tank during refueling. Please see attached file that documents the problem and possible solutions. I also recommend sharing your many complaints on this problem with the EPA as the problem is also in their area.