Ted Mooney, P.E. RET
- Pine Beach, NJ
The authoritative public forum
for Metal Finishing since 1989
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Corrosion in Ford diesel fuel tanks
(Photos courtesy of Chris R.; see page 3)
We have also experienced the delamination problem in our 2005 Ford F350 work truck. We brought it to our local Ford dealership to have it repaired. Even though our truck is still within the warranty period Ford refuses to cover the problem because they do not consider it a manufacturer's defect. They blame the diesel fuel companies also. We spoke with a Ford customer service representative and he said the 2005 Ford truck was manufactured for the diesel fuel specifications at the time. He said that an additive had been added to the diesel fuel after the manufacture of our vehicle at the time the sulfur
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in the diesel fuel was reduced from 500 parts per million to 15 parts per million. He said the additive was only added in the Northeast section of the country. He also said that other people who have experienced the same problem have put in a claim to their insurance companies and have been reimbursed for the repairs to their vehicles. We first experienced the problem in March 2008. Our vehicle was not even three years old yet. The delaminated material is the lining of the fuel tank. The mechanics at the Ford dealership and our insurance adjuster both identified it as such. The lining had corroded to such an extent that it flowed into the fuel injectors and caused them to fail. The total cost of the repair to our truck was just under $6,000.00. Upon investigating the matter further, I have learned that the same exact fuel tank is also in our 2006 and 2007 Ford F350 work trucks. Our insurance company has not yet paid the claim to have the truck repaired, they are still waiting to hear a response back from Ford Motor Corp. When we spoke to the Ford customer service representative, he said Ford was aware of the situation and that it may cause their market share to drop, and lose them some customers, but they would not take the responsibility for causing admitting to the delamination problem as being their fault. I did receive an invitation from our local Ford dealership to attend a free training seminar on Diesel Fundamentals, the upkeep and maintenance of Diesel vehicles.
landscape construction - Bedford, Massachusetts
May 23, 2008
A. I am not one to believe in class action law suits but this issue has me on the verge. I purchased a new ford f450 in 2000 with a diesel engine. About two years ago I started having problems with it losing power. After two wiring harnesses ($1000) each and two new fuel tanks (also a grand each) and one in tank fuel pump ($900) I am convinced that the problem is with gas tank delamination. The second gas tank which was put on by the dealer went bad after 12000 miles and less than one year. The dealer would not warranty. Since I live in Ohio they state that Ohio does not regulate fuel and therefore they will not warranty. I know that many fuel tanks have been replaced and not covered under warranty, unfortunately I am not internet savvy enough to start a page to gather all the victims together. If anyone is aware of a site that I could get on a list please let me know. For the record, we get 90% of our diesel fuel from one service station. I have never used Bio fuel. Since having my tank relaminated at a radiator shop, I have not had any problems. Thanks for your time.
Michael A. Clar- Copley, Ohio
June 19, 2008
Q. We have experienced the same problem with fuel tank delamination in our 2002-2003 Ford F450 diesel ambulances. Ford participated in replacing the fuel tanks, sending units, and fuel pumps in 5 of our vehicles 9 months ago. Today I have 2 of the same units with fuel systems clogged with rust. The lower half of the tanks are covered in rust. Does anyone have a source for aftermarket replacement tanks I could install that won't have the same issues? I can't afford to continue to have problems with ambulances.
Denny Kincade- Yorktown, Virginia
June 24, 2008
!! Because I am have the same problem with fuel tank delamination with our Ford ambulances for the second time I have filed a complaint with NHTSA. Maybe if everyone else files a complaint it might force Ford into doing something.
Denny Kincade [returning]- Yorktown, Virginia
June 26, 2008
!! I just got a phone call from NHTSA. The gentleman I spoke with said he has been working on this issue for a year trying to get a recall. He said if I knew anyone else with this problem to have them contact NHTSA. You can do so very easily at nhtsa.gov
Denny Kincade [returning]- Yorktown, Virginia
July 7, 2008
My friend and myself have the same problem with our e350 work vans. He spent $5,000 over a year ago replacing his tank, fuel lines, injectors, and pump, and I'm replacing my fuel tank, pump and pickups as I write. Symptoms were identical, the vans would start to run like crap then lose power and finally we would have to pull over because we could only do 5 mph or less. We would turn the engine off, wait 5 min., restart the engine and it would run as if nothing was wrong. Obviously this problem was intermittent and was always present going up large hills when the engine would need lots of fuel/power. No doubt about Ford needs to own up to this issue and, if nothing else pay half the cost. Good luck fellas.
contractor - Milford, Connecticut
June 29, 2008
I purchased a new 2004 6.0 e-350..
@ 28000 mi. the fuel tank delaminated Ford replaced the tank in 06 under my 3/36..
Then@43000 mi. just 14000 mi. on the new tank it delaminated again..this time it cost me 2100.00..
my dealer said ford will not admit to the problem or for the same reason confirm a fix. My dealer can't tell me it's not going to happen again. I contacted a Ford exec. he says it's the fuel. I say in N.Y. the fuel is regulated 5%..I use only Hess diesel, my previous 7.3 lasted 18 years with one tank. I am taking the dealer to small claims court..they installed a defective tank. my lawyer said it's between ford and the dealers we should not have to pay for a defect..3 tanks in four years says it all
robert selleck- islip new york
July 16, 2008
September 23, 2008
My dad bought a 2005 Ford F450. He drove it into the dealership because it was running sluggishly. After a diagnostic, he was informed that the fuel filter was dirty. He told the tech to replace the filter. The tech asked him to wait in the waiting room. 15 minutes later, he returned to the garage and the tech tells him that the vehicle will no longer run and to repair it will cost $5,000+. He said there was debris in the tank caused by fuel contamination.
The debris looks like the material that has been described in this blog.
We towed the vehicle to another dealer and he removed the fuel tank and told us to call the California Bureau of Automotive Repair. He says the lining of the tank peels off and the material from the lining is clogging the fuel pump.
I'm in California and I know there are regulations on diesel.
- San Francisco, California
I have 11 diesel trucks and 5 tanks have been replaced over the past 6 months. It sounds like the same problem of everyone else who posted on this site. Rusty sludge and rust throughout the tank. I will contact nhtsa to try to recoup my expenditures. I've spent three to five thousand on each truck.
- Rocky Hill Connecticut
September 26, 2008
I posted back in September 2008 and things have gotten worse, I run a fleet of thirty intermediate trucks. Twenty Fords, Four International and six GM/Isuzu. They all run on the same fuel from the two gas stations that we use. The only vehicles that have a fuel tank problem are the fords 2000 and up. We have older ford 2-99s, 1-96 and 1-94 that are more reliable than the 2006s. Just like everyone else, we start by replacing the costly injectors that the ford computer points its finger to. Then you continue with all the other repairs before you realize its the tank again. We thought it couldn't continue happening year after year with the newer truck purchases but it looks like Ford never cared to make the changes or they would accept fault in their design.
George Li [returning]- Rocky Hill, Connecticut
January 18, 2012
A. After a lot of run around, Ford admitted that the problem is that bio-fuels are causing "delamination" of the interior of the tank, clogging fuel filters and ruining injectors. Meanwhile, we're out $3,300 in tank replacement and other work and Ford says "sorry" must be bio-fuel in the diesel--tough.
Keith Zagar- Dallas, Texas
October 9, 2008
A. I have just had this problem in one of my six trucks my problem with Ford is that there are "it is what it is" but Chevy and Dodge is not having this problem.
Robert Beno- Baltimore, Maryland
November 13, 2008
I have a 99 Ford e 350 with the same problems. Last year I put in a goldenfuel svo kit. It ran fine for 6 months then I began having problems with the diesel side. I would just idle on diesel for a while then run on straight vegetable oil for the duration of my trip. Knowing all along there was something wrong with the diesel side from the solenoid back, I figured it had to be in the tank. No mechanic wanted to touch it. Eventually it began to shudder on diesel and svo.
I finally dropped the diesel tank and took a look. The entire bottom was covered in the same gray flakes everybody else is reporting. I cleaned it out. Scrubbed the sides where it was still peeling, then cleaned it again. Changed the filter, and put it back together. It ran great for two days then started having the same shuddering problems at speeds of about 50 and up. Tomorrow I am taking the fuel intake line apart and trying to clean that out. There is probably a good amount of this sludge in it. Also possibly in the diesel/vegetable oil solenoid and fuel pump. I hope this works. The thought of taking apart the injectors and replacing the fuel pump does not sound like a fun project I want to do or fund. Many people were talking about at least complaining to Ford. I guess I will too.
Tampa, Florida
November 17, 2008
I also have 2 ford F550 1 06 and 1 07 both have had tanks replaced just had 3rd tank in each truck same problems pumps and sending units filters injectors. I have fought with ford each time the last tank lasted exactly 13 months just 1 month over warranty of new tank. It's a big scam no problem with my Chevys or Dodges Dodge has 130,000 miles. we need a class action law suit I hate law suits but I know 30 plus ford truck owners with same problem cost over 3000 dollars each. But ford will not own up to it. my dealer mechanic tells me they do 40 tanks a month. Now that's not an isolated incident. Thank you. Let's all pull together and get our money back. and make ford recall and make plastic tanks. My dealer said it from the tank not being insulated maybe because the problem is exclusively on rack,flat, and dump models ( chassis cab models) says that the pickups are not subject to because tank is not out in open like our trucks. They also say to keep tank full so it don't rust out but our trucks you cannot fill tank to top because of where the fill tube is its 3 inches lower than top of tank. Thank you
- Shirley, New York
December 29, 2008
A. Enter a complaint at NHTSA.GOV
I have been having the same problems as everybody on this post. Ford dealer wants $2,700. for the repair.
They want to replace the fuel tank with another Ford fuel tank. If they do, the problem will return in a few thousand miles and I can't afford to keep replacing fuel tanks because Ford can't make them right.
I am going to replace the tank with an aftermarket tank manufactured by Transfer Flow Inc and see what happens. They offer a replacement tank for my 2004 F450 for about $700.00. A lot less than Ford charges. I will try to post the results of the replacement tank installation.
I also entered a complaint with NHTSA.GOV about this problem and searched their site for other complaints about this problem. I COULDN'T FIND ANY OTHER COMPLAINTS!
Get off your duff and file a complaint. Nothing will happen unless you take the time and file a complaint. Geez, finding time to rant but not filing an official complaint is just dumb.
- Steger, Illinois
December 31, 2008
I am having similar issues. I had the truck in for repairs 13 months ago and Ford replaced the fuel injectors and filters because it was under warranty. The same problem just occurred December 29th 07 just two months out of the original warranty even though it is still covered under the extended warranty. Ford is refusing to repair the problem due to "bad fuel". I have filed a complaint with NHTSA, I am lodging a complaint against the dealer with the BBB. Everyone please lodge your complaints so this will move forward.
- Dallas, Texas
January 7, 2009
January 21, 2009
This is in response to my Jan 7th 09 post: I received a phone call today from Ford and they refused to pay. They blamed the fuel. I asked for this in writing and they refused even though my car is under an extended warranty.
They refused to state in writing what the problem is!
Here is my course of action
1. Bleed Ford of money.
File a small claim case. if you win, the problem is solved, if you lose then you can refile in a regular court. It is perfectly legal to take the same case to small claims court and later into a municipal court. Ford will have to provide a lawyer in both venues and cost them well above the price of the repair. Threaten to do the same to the dealer. They will have to provide a lawyer too.
2. Fill a complaint with the BBB. This works better against dealers then Ford but anything to raise the pressure on Ford.
3. Log a complaint with NHTSA.GOV
4. Require a written letter from Ford detailing the reasons for the failure. Diesel providers will hopefully get involved at that point once Ford places the blame on another industry.
email me with information - I have a lawyer who has agreed to get involved (he took on Nokia and won)
put FORD in the title.
- Dallas Texas
Four months ago, one of our 2006 LCF trucks (with only 5700 miles!) had the entire fuel system replaced including both side-mounted tanks which had the same symptoms. I'm sure the cost would have been in excess of $6000, but I never saw the total since it was repaired under warranty. At the time, I thought it was an isolated incident. I just found out about this problem yesterday when my dealer told me it would be $5400 to replace the entire fuel system on our 2005 F-550 (with 19,000 miles). This vehicle is about 6 months out of warranty. I also have a 2002 E-450, 2004 F-550, & another 2006 LCF truck, in addition to some GMC's - all are diesels. Our fleet averages only about 13000 miles on each vehicle. I am now concerned about the rest of the Ford fleet. After reading this blog, I pulled the F-550 from the dealership and will have it repaired at a private shop. I had to pay the extra towing and a diagnostic fee to the dealership. From this point forward, I REFUSE to give Ford another dime until I'm reimbursed. Both of my 2006 vehicles were bought in 2007 after this problem had already come to light. I am outraged that I was KNOWINGLY sold 2 trucks that are defective. I will definitely complain to higher authorities and am willing to participate in any class-action lawsuit that may arise.
- Vienna, Virginia
January 9, 2009
!! Our 2006 Ford LCF has been in the shop twice for running sluggishly and having difficulty starting. Once in December 2007 and again in January 2009. In Dec. '07 three injectors were replaced and fuel filter was replaced under warranty. This time three more injectors need to be replaced and they say the fuel tank is bad, blaming in on bad diesel contaminating tank causing the liner to fail. I purchase from Shell and Green Spot. We contacted owner of Greenspot here in Dallas, who said his fuel meets all government standards. He also happens to be an attorney. He assures it's not the diesel, it's the tank. He also suggested taking the Dealer and Ford to small claims court. Then sue them again. Ford needs to take responsibility for their product and recall these tanks immediately. It's difficult to start a class action suit in Texas, but if there is anyone in another state who wants to start one. Let's do it!
David Prince- Dallas, Texas
January 14, 2009
Q. I have a 2002 f-350 7.3 was plowing and truck just started stalling out checked fuel filter and was amazed at condition end up pulling top off tank and bottom was coated with what appeared to be all metal shavings had to change pump,filter, empty tank clean and refill with new fuel but question is how often will this occur very concerned only 48,500 miles
Joe DiOrio- Barrington Rhode Island
January 20, 2009
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