Thirty complaints cover fuel leaks, exhaust fumes in the cabin, and fuel pump failures on 2013 Explorers.
Fuel tank leaks are the most common problem. Owners smell gasoline inside the cabin or notice puddles under the vehicle, sometimes within the first few months of ownership. Some tanks crack at the filler neck or delivery module; others show rust and corrosion, particularly around the sending unit. Multiple owners' VINs were excluded from recalls 13V227000 and 15V812000 despite having identical failures. One dramatic case involved an explosion on the highway that dumped the entire fuel tank, narrowly avoiding fire. Dealerships struggled to obtain replacement parts, leaving owners in rental cars for months while waiting for inventory.
Exhaust fumes and carbon monoxide enter the cabin through AC vents, especially during hard acceleration or stop-and-go traffic. One owner's independent testing confirmed harmful carbon monoxide levels, higher in the rear seats. Technical Service Bulletin 12-12-4 is mentioned repeatedly but consistently fails to fix the problem. Children have reported headaches, nausea, and bronchitis; one owner's dog became sick from the fumes.
Fuel pump failures cause starting difficulties, stalling, and loss of power while driving. One vehicle stalled on the highway in rain and wouldn't restart.
Fuel delivery module and injector leaks trigger check engine lights and strong odors. Repairs were costly and often incomplete. Owners describe frustration with dealer communication delays and refusals to address safety concerns.
Failure modes owners describe
Fuel tank leaks and gasoline odor inside cabin
Fuel tanks crack, corrode, or fail at the filler neck or delivery module, causing gasoline to leak and strong fuel odors inside the vehicle. Multiple owners report leaking discovered visually under the vehicle or in garages, with some experiencing fuel pooling on the tank or ground. Several VINs not covered by recalls 13V227000 or 15V812000.
When: Most often early in ownership (months to a few thousand miles); some occur around 80,000–200,000 miles
Symptoms owners cite: Strong gasoline odor inside cabin when starting or moving to passenger seat; Gasoline smell from outside the vehicle; Visible fuel pooling under tank or in wheel well; Smell in garage where vehicle is parked; Fuel on top of tank
Repairs/costs cited: Fuel tank and fuel pump replacement required; parts were difficult to obtain and delayed service (months of wait). Some owners paid for independent diagnosis of fuel delivery module or sending unit corrosion.
Recalls/TSBs owners mention: NHTSA Campaigns 13V227000 and 15V812000 issued; many owners' VINs not included in recalls. Dealers unable to obtain parts for months. One owner waited until October for parts after June complaint. Ford regional manager stated 'nothing happened so it can't be considered' for safety upgrade. Manufacturer referred some complaints to NHTSA Hotline.
Explosive fuel tank rupture
Owner reported a loud explosion in the fuel tank area while driving on the highway, resulting in immediate loss of all fuel and loss of power. Fire department applied putty to multiple leaks. Owner had just filled tank and feels lucky to have avoided fire.
When: Occurred while driving highway; vehicle had been serviced at dealership less than a week prior
Symptoms owners cite: Loud definitive explosion near fuel tank area; Immediate loss of power; All fuel dumped out
Repairs/costs cited: Fire department applied putty to fuel tank leaks; vehicle required extensive repair
Recalls/TSBs owners mention: No recall notification provided despite vehicle being at same dealership one week prior. Owner had specifically requested all applicable recalls be checked before release.
Exhaust fumes and carbon monoxide entering cabin via AC vents
Exhaust odor (often described as sulfur smell or burning plastic) enters cabin through air conditioning vents during acceleration, idling, or stop-and-go driving. In some cases, harmful levels of carbon monoxide have been measured inside the vehicle, both while driving and at idle. Technical Service Bulletin 12-12-4 (exhaust system repair) does not resolve the issue.
When: Throughout ownership; some complaints from early months of ownership
Symptoms owners cite: Strong sulfur or exhaust odor in cabin through AC vents; Odor worst during hard acceleration; Odor lasts approximately 30 seconds then stops; Fumes in cabin during stop-and-go traffic and idle conditions; Foul burning-plastic smell; Higher carbon monoxide levels in rear and third-row seats; Passenger discomfort and illness (headaches, nausea, bronchitis in children)
Repairs/costs cited: TSB 12-12-4 performed on some vehicles without fixing the issue. One dealer blamed a plastic bag in exhaust. One authorized dealer replaced air extractor by rear bumper—remedy failed. Most repairs unsuccessful.
Recalls/TSBs owners mention: Technical Service Bulletin 12-12-4 issued but ineffective. Dealership assured one owner no carbon monoxide was present; testing proved otherwise. Manufacturer did not offer solutions. One complaint related to Campaign 15V812000 but vehicle not included. Ford confirmed exhaust fumes entering vehicle but refused to fix (per one owner).
Fuel pump failure and starting/stalling issues
Fuel pumps fail, causing difficulty starting or complete failure to start. One vehicle stalled on highway and would not restart after several attempts. Another stalled repeatedly over time with increased frequency before complete failure to restart.
When: Occurred at 79,000 miles to 121,000 miles; one occurred during highway drive in rain with 3.5L turbo engine
Symptoms owners cite: Failure to start immediately; Vehicle stalls and fails to restart; Loss of motive power while driving; Shaking, shuddering, and stalling during acceleration; Check engine light illumination
Repairs/costs cited: Fuel pump replacement needed. One vehicle required coasting off highway and overnight hotel stay. Independent mechanic diagnosed faulty fuel pump on one vehicle.
Recalls/TSBs owners mention: Manufacturer advised filing NHTSA complaint and taking vehicle to dealer. No recall or assistance provided.
Fuel injector leaks and check engine light
Fuel injectors leak, triggering check engine warning light. Dealership diagnosed the issue but owner declined repair due to cost. Temporary fix of purge valve replacement performed by independent mechanic did not resolve the underlying problem.
When: Occurred at approximately 93,000 miles
Symptoms owners cite: Check engine warning light illumination (intermittent after repair); Abnormally strong fuel odor from front of vehicle; Failure to start after refueling; Vehicle shudders during starting attempts
Repairs/costs cited: Dealership identified leaking fuel injectors but repair not completed due to cost. Independent mechanic replaced purge valve as temporary measure; check engine light continued intermittently.
Recalls/TSBs owners mention: Manufacturer informed owner that VIN not included in Campaign 13V227000 or 15V812000.
Fuel delivery module fracture and leaking
Fuel delivery module fractures or fails, causing fuel to leak underneath the vehicle. In some cases, a 'check fuel delivery system' message displays on the instrument panel.
When: Occurred at 82,736 miles to 98,000 miles
Symptoms owners cite: Strong gasoline odor outside vehicle when parked; Fuel leaking underneath vehicle; Check fuel delivery system message on instrument panel
Repairs/costs cited: Independent mechanic diagnosed fractured fuel delivery module. No repairs completed in reported cases.
Recalls/TSBs owners mention: Campaign 13V227000 and 15V812000 applicable to some; manufacturer informed one owner vehicle was previously repaired under recall as one-time free repair. Dealer informed another owner VIN not included in recall.
Rust and corrosion on fuel tank and sending unit
Rust develops on fuel tank and sending unit, causing cracks and leaks. One dealership specifically identified rust on sending unit and tank as cause of failure.
When: Occurred around 100,000 miles
Symptoms owners cite: Strong gasoline odor when approaching vehicle; Puddle of gasoline under vehicle
Repairs/costs cited: Dealer diagnosed rust on sending unit and fuel tank causing tank crack and leak; vehicle not repaired in complaint.
Recalls/TSBs owners mention: Manufacturer referred contact to NHTSA Hotline for assistance.
Synthesized from 30 NHTSA owner complaints — unverified consumer
allegations, summarized for patterns. The verbatim filings appear below.