Owners of 2007 Ford Edges report widespread fuel tank failures caused by corrosion at the welded seams of the two-piece steel tank. The failure shows up as a persistent fuel odor, sometimes taking weeks to appear, followed by visible dripping or pooling of gasoline underneath the vehicle or in the garage. Owners describe small leaks that progress to steady drips and larger seeps. The tank exterior shows rust and wetness; some report holes rusted through the top or left rear corner of the tank. Failure occurs independently of accident history or maintenance—many tanks were in garage-kept vehicles that were never damaged or abused.
Owners report being unable to fill the tank completely after failure appears; one can only add 4 gallons, another limited to half-tank. After a repair or failed diagnosis, the vehicle must sit on a level surface to prevent further leaking. One nearly-new vehicle (2,700 miles) also exhibited fuel spraying from the filler neck during refuel, soaking the driver's clothing and triggering a tank cap warning light.
Ford issued NHTSA Campaign 14V682000 to address fuel tank corrosion, but many 2007 model VINs were excluded or removed from the campaign after inspections found no defects at the time. Ford recalled 2008 Edges for the same issue but declined to extend the recall to 2007 models. Replacement tanks cost $1,500–$2,300 plus labor; dealers reported parts going on national back order, and Ford stated at least once that replacement tanks were unavailable and no supplier could manufacture them. Owners received no reimbursement from Ford and were denied warranty coverage.
Failure modes owners describe
Fuel tank seam corrosion and leakage
Two-piece welded steel fuel tank develops rust and corrosion at the seams, causing fuel to seep or drip from the joint. Owners report gasoline odor both inside and outside the vehicle, puddles of fuel under the vehicle, and steady drips. The failure occurs independent of accident history or tank maintenance. Multiple owners note the tank was garage-kept and never damaged.
When: 50,000 to 155,000 miles; some owners report issues as early as a few months of ownership (2,700 miles reported on one nearly-new vehicle)
Symptoms owners cite: Persistent or intermittent fuel odor inside and outside vehicle; Visible fuel dripping or pooling under vehicle; Wet fuel tank exterior; Fuel leak during or after refueling; Fuel fumes in garage when parked
Repairs/costs cited: Tank replacement required; owners cite parts cost of $1,500–$2,300 plus labor ($600 reported). Some dealers placed parts on national back order. One owner reported Ford stated they had no replacement tanks available and no supplier to manufacture them. Owners unable to fill tank to full capacity post-failure (one limited to 4–5 gallons, half-tank mark). Vehicle must be parked on level surface to prevent further leakage.
Recalls/TSBs owners mention: NHTSA Campaign 14V682000 (Fuel System, Gasoline recall) issued; however, many 2007 model VINs were either not included or were later removed from the campaign after recall inspection found no defects at the time. Ford refused reimbursement for out-of-pocket repairs and denied responsibility, claiming no design defect. Parts were unavailable to complete recall repairs. Ford 2008 Edge models were recalled for the same issue, but 2007 models were not included in that recall.
Fuel filler neck overpressurization and gasoline spray
When refueling after the automatic shut-off clicks, gasoline sprays out of the filler neck rather than being contained. Owner states the tank is not venting properly, forcing air out during refill and pushing gasoline with it. Occurred on a nearly-new vehicle (2,700 miles, 2+ months old).
When: 2,700 miles (early in vehicle ownership)
Symptoms owners cite: Gasoline sprays out of filler neck after pump shut-off click; Fuel soaks occupants' clothing; Tank cap warning light illuminates
Repairs/costs cited: Dealer replaced filler neck. Door seals and paint (primer/clear coat) issues also addressed at dealer during same service visit.
Recalls/TSBs owners mention: Ford initially declined responsibility, stating it was the dealer's responsibility to inspect the vehicle and remedy defects within 30 days of sale. Dealer completed replacement and repair work; owner made 7 dealer visits and drove 700 miles for warranty work.
Fuel rail test port leak
Fuel seeps from the fuel rail (fuel supply manifold) at the test port connection point. Detected as gasoline smell in engine compartment. Dangerous because hot engine parts are in close proximity and could ignite leaking fuel.
When: Early in vehicle use (detected after 80 miles of driving)
Symptoms owners cite: Gasoline smell in engine compartment; Visible fuel seeping from fuel rail test port area
Repairs/costs cited: Ford dealer determined fuel rail port was not repairable; complete fuel rail replacement required. Owner had vehicle towed.
Synthesized from 36 NHTSA owner complaints — unverified consumer
allegations, summarized for patterns. The verbatim filings appear below.