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severe 15 complaints filed with NHTSA · avg repair $1,200 · see fuel system across all vehicles →
If left uncorrected, a fuel leak could eventually develop. A fuel leak in the presence of an ignition source could result in a fire.
The manufacturer has issued service bulletins covering fuel system on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
ERRATIC FUEL GAUGE OPERATION - MIL ON --DTCS P040/P0463 OR INSTRUMENT CLUSTER MODULE DTC B1201--VEHICLES BUILT BEFORE 12/3/2007.
full bulletin at NHTSA ↗EMISSION RECALL. SOFTWARE COULD CAUSE THE CATALYST MONITOR TO STOP FUNCTIONING WHEN CHANGING FUELS.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
Owners of 2007 F-150s report serious fuel-system and related engine issues. The most dangerous: fuel pump control modules fail intermittently or completely, killing the engine without warning and cutting power to steering and brakes on the freeway. One owner had the module replaced twice (at 14,000 and 24,446 miles) at roughly $500 each. Another broke down on I-75; another experienced an engine compartment fire at 52,000 miles, traced to a fuel crossover line failure by the fire chief.
Fuel lines themselves leak or rupture—two holes found in one line at 18,200 miles, another leak at 155,000 miles. Fuel sending units fail, leaving the truck unable to start or with a fuel gauge stuck on empty. One owner paid $407 for a sending unit at 118,000 miles.
A driver control module electrical plug melted during a fuel pump repair, suggesting poor placement or design. One owner reported unintended acceleration three times over three years, culminating in a collision with a building. Coil pack failures on the 4.6L V8 have blown spark plugs out of the cylinder head, requiring costly head repair.
Cold-climate owners note that repairs should not be necessary this early in the vehicle's life.
Same Ford F-150 fuel system reports on nearby years: 2005 · 2006 · 2010
The fuel pump control module fails intermittently or completely, cutting fuel supply to the engine and causing the truck to stall without warning. Loss of engine power results in loss of power steering and brake assist, creating a dangerous situation especially at highway speeds.
When: First failure around 14,000 miles; second replacement at 24,446 miles. Also reported on freeway; one case at 52,000 miles with engine fire.
Symptoms owners cite: Engine stalls suddenly while driving; Loss of power steering assist; Loss of brake assist; Engine will not restart or restarts after intermittent stalling; Multiple module failures on same vehicle
Codes mentioned: Fuel pump control module electrical failure
Repairs/costs cited: Fuel pump control module replacement; cost approximately $500 per replacement. One case also involved replacing driver control module and electrical plug that began to smoke and melt; repair cost $350–$421.
Recalls/TSBs owners mention: No recalls or TSBs mentioned; one owner noted vehicle not included in NHTSA campaign 07V278000.
Fuel lines develop leaks or rupture, creating fuel odor inside and outside the vehicle and risk of fire. One case involved two holes in the fuel line; another involved fuel crossover line failure that resulted in engine compartment fire.
When: 18,200 miles; 55,287 miles; 52,000 miles (fire case); 155,000 miles.
Symptoms owners cite: Strong fuel odor inside and outside vehicle; Fuel leak visible, especially after refueling; Engine compartment fire; Check engine light illuminated intermittently (one case)
Codes mentioned: Fuel system leak, Fuel crossover line failure
Repairs/costs cited: Fuel line replacement. In fire case, fuel crossover line was identified as failure point by fire chief investigator.
Recalls/TSBs owners mention: One owner referred to NHTSA campaign 07V278000 (Fuel System, Gasoline); another vehicle stated it was not included in that campaign.
Fuel sending unit fails, preventing engine start and causing incorrect fuel gauge reading.
When: Not specified in narratives; one case at 118,000 miles.
Symptoms owners cite: Vehicle will not start; turns over but will not fire; Fuel gauge reads empty when tank is full
Codes mentioned: Fuel sending unit failure
Repairs/costs cited: Fuel sending unit replacement; cost $407.
Electrical plug to driver control module smokes and melts during operation, indicating a short or overload condition.
When: During fuel system repair on vehicle with blown #9 fuel pump fuse.
Symptoms owners cite: Electrical plug to driver control module smokes and melts; Vehicle runs only briefly after initial repair before electrical failure
Codes mentioned: Fuel pump fuse blown, Driver control module electrical fault
Repairs/costs cited: Driver control module and electrical plug replaced. Owner noted poor placement of control module (reportedly near fuel tank rather than near fuse box or firewall).
Inferior plastic on fuel pump assembly develops cracks or leaks, allowing fuel vapor to escape.
When: Not specified.
Symptoms owners cite: Fuel vapor leak from fuel pump assembly
Truck accelerates forward when shifted into Drive despite driver's foot being on the brake. Owner alleges this happened multiple times over several years on the same vehicle.
When: First incident about 1 year before initial complaint; second incident 3 months later; third incident April 12, 2009 with 14,454 miles on truck.
Symptoms owners cite: Vehicle accelerates forward when shifted into Drive; Brake pedal depressed but truck still accelerates; Multiple occurrences on same vehicle
Repairs/costs cited: No repairs mentioned; owner filed complaint after third incident resulted in collision with building.
Coil pack fails and blows spark plug out of cylinder head on 4.6L V8, requiring both coil pack replacement and cylinder head repair kit.
When: Two occurrences within 3 months; vehicle had no specified mileage.
Symptoms owners cite: Engine shuts off and will not restart; Loss of engine power while driving on highway; No power steering
Codes mentioned: Coil pack failure, cylinder #3
Repairs/costs cited: Coil pack replacement; cylinder head repair kit to fix stripped threads from blown spark plug.
Synthesized from 15 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
It's a meaningful issue. 15 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $1,200.
Across the 12 complaints that reported odometer mileage, most fuel system failures cluster between 52,000 and 99,947 miles, with the median around 55,287. A quarter of owners report trouble before 52,000; a quarter make it past 99,947. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
Independent shops typically charge around $1,200 for fuel system repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Yes — 1 active recall(s) cover fuel system issues on this vehicle. Recall fixes are always free regardless of mileage or warranty status. Use the VIN decoder at the top of the page to check if your specific vehicle is affected.