Owners describe a cluster of fuel-system issues tied to defective fuel tanks, purge valves, and fuel delivery modules. The most consistent complaint is unexpected stalling after refueling or during normal driving. Fuel tank failures fall into two categories: expanded or deformed tanks causing fuel to escape under pressure, and collapsed tanks trapping or crushing the fuel pump. Multiple owners report fuel gauges that stick, display wildly inaccurate readings, or require a restart to correct—leading to surprise empty tanks at highway speeds.
Starting problems are frequent: vehicles won't fire immediately after refueling and require multiple attempts or hard pedal priming. Rough idle, especially post-refueling, appears alongside hesitation during acceleration and sputtering at stops. Check engine lights illuminate, often pointing to purge valve or EVAP codes (P0456, P1450). Several owners cite a directly injected engine design coupled with dual-clutch transmission that compounds symptoms through rough starts and loss of power under load.
The recall situation muddies things considerably. Many owners report repair attempts under NHTSA Campaigns 18V735000 and 19V515000, but only PCM software updates were performed—not the fuel tank or delivery module replacements the owners believe they need. Dealers claim recalls are closed or parts weren't defective at recall time, leaving owners unable to get free repairs for recurring failures. A handful note that recall parts became unavailable, delaying or blocking repairs entirely. Owners describe being stranded on roadsides and interstate highways when tanks unexpectedly empty, creating genuine safety hazards.
Failure modes owners describe
Fuel tank expansion/deformation/collapse
Fuel tanks expand, deform, or collapse under normal use. Expanded tanks release fuel pressure during refueling; deformed or collapsed tanks crush the fuel pump or trap fuel.
When: Reported between 33,000 and 200,000 miles; some failures occur within first year of ownership
Symptoms owners cite: Significant pressure released when refueling; Fuel gauge inaccurate or stuck; Unexpected stalling during or after driving; Vehicle deceleration and loss of motive power at highway speeds; Check engine light illuminated
Codes mentioned: P1450 (fuel system pressure), P0456 (EVAP small leak)
Repairs/costs cited: Fuel tank replacement required; dealers and independent mechanics confirm tank damage. Costs not cited by owners. Some owners report repair denial because tank appeared intact at previous recall service.
Recalls/TSBs owners mention: NHTSA Campaign 18V735000 and 19V515000 addressed fuel system issues via PCM software update and purge valve inspection. However, fuel tanks were not replaced under these recalls. Dealers later claim recalls are closed and cannot be reopened, or that tanks were not defective when recall work was performed. Some owners report parts remain unavailable from dealers.
Fuel gauge malfunction
Fuel gauge fails to read accurately, sticks at incorrect levels, or requires vehicle restart to display true fuel state. Owners run out of fuel unexpectedly despite gauge showing remaining range.
When: Typically reported 100,000+ miles but occurs as early as within first year; recurs after refueling cycles
Symptoms owners cite: Gauge reads 8–17 miles or 1/4–3/4 tank when fuel is actually depleted; Gauge moves erratically or not at all until key-off restart; Vehicle stalls on highway due to actual empty tank while gauge shows fuel remaining
Codes mentioned:
Repairs/costs cited: Calibration attempted at dealership; owner reports calibration reduced range from 144 miles to 133 miles before re-stalling. No permanent fix reported.
Recalls/TSBs owners mention: Dealers calibrated fuel gauge on at least one vehicle without resolving the underlying issue. No recall remedy addresses gauge failure directly.
Post-refueling hard start and stalling
After refueling, vehicle fails to start immediately, requires multiple ignition attempts, hard acceleration pedal input, or extended cranking before firing. Engine stalls 2–3 times on initial startup following fuel addition.
When: Immediate to within weeks of ownership; persistent through vehicle lifetime
Symptoms owners cite: Vehicle won't start immediately after refueling; Multiple restart attempts needed (5–10 seconds of cranking); Rough idle on first start after refueling; Engine stalls within 100 yards of initial startup post-fuel; Erratic idle at 2000 RPM before settling or stalling again; Check engine light illuminates post-refueling
Codes mentioned: P0456 (EVAP system leak), P1450 (fuel system pressure)
Repairs/costs cited: One owner reports fuel tank starting to concave on bottom. Purge valve replacement attempted on some vehicles but symptoms persist. Dealers cite EVAP and purge valve issues; one owner notes fuel system cleaning and fuel induction service performed without resolving stalling.
Recalls/TSBs owners mention: NHTSA Campaign 19V515000 (PCM reprogramming) and 18V735000 (software update) were applied but failures recurred. Dealers state recall repairs are complete and closed. Purge valve replacement offered only outside recall coverage. One owner reports 'common problem' acknowledged by dealer but not subject to recall.
Loss of power and hesitation under acceleration
Vehicle loses motive power, hesitates, or fails to accelerate when gas pedal is depressed, especially during traffic maneuvers (left turns crossing traffic, merging, hill climbs). Power loss can occur mid-turn or mid-acceleration.
When: Early in ownership (within first weeks) through 130,000+ miles
Symptoms owners cite: Vehicle hesitates during 0 to >0 acceleration (gradual or hard pedal); Almost-stalled conditions during normal driving maneuvers; Vehicle loses power at 35–75 MPH; Rough/bogged acceleration requiring hard pedal press to move; Vehicle sputters during acceleration from stop; High RPM but failure to accelerate as intended; Engine stumbles when starting from complete stop on incline
Codes mentioned: P0456 (EVAP leak)
Repairs/costs cited: One owner's dealership attributed symptoms to dual-clutch transmission electronic behavior and direct injection design as 'normal.' No repair offered. Independent mechanic noted fuel tank vacuum pump defective.
Recalls/TSBs owners mention: Dealer service manager cited direct injection and electronic clutch as design features, not defects. No recalls specifically address hesitation. One owner noted Ford's investigation of similar issue on F-150 direct-injection vehicles.
Rough idle and shuddering
Engine idles roughly or shudders, particularly at idle after refueling, at stoplights, or in park/neutral. Steering wheel vibrates during idle. Vehicle may roll backward on inclines despite brake application.
When: Reported from early ownership through 160,000 miles
Symptoms owners cite: Rough idle in park or in gear with brake applied; Shuddering and jerking at startup after refueling; Abnormal loud whining sounds at 50–60 MPH; Steering wheel vibration while idling; Vehicle rolls backward on incline from dead stop; Vehicle shudders and vibrates when accelerating
Codes mentioned:
Repairs/costs cited: Transmission computer module replaced on one vehicle due to shuddering and incorrect shifting. Purge valve replacement attempted on others without resolving idle issues. Fuel system cleaning performed without success.
Recalls/TSBs owners mention: One dealership explained rough idle as normal behavior of direct injection combined with electronic clutch transmission. No recalls directly address idle quality.
Fuel loss and overfill restriction
Fuel rapidly evaporates from tank, or vehicle fuel door/filler neck prevents adding normal fuel quantities. Some vehicles accept only 3 gallons before refusing more fuel.
When: One owner reported issue starting after recall service. Another noted issue ongoing since 2018 (previous owner).
Symptoms owners cite: Fuel level drops rapidly after refueling without driving; Unable to add more than 3 gallons of fuel when filling tank; Fuel amount added decreases over time compared to baseline; Fuel evaporation noticed soon after refueling
Codes mentioned:
Repairs/costs cited: Vapor canister replacement recommended by dealer on at least one vehicle.
Recalls/TSBs owners mention: One owner noted recall repair (campaign 18V735000 or 19V515000) preceded the fuel overfill restriction. Vapor canister identified as defective but repair cost to owner.
Engine stalling without warning at stop or low speed
Engine shuts down unexpectedly while vehicle is stopped at traffic lights, in park, or during low-speed maneuvers (reversing, turning). Vehicle can be restarted but may stall again immediately.
When: As early as 45,260 miles; reported throughout vehicle lifespan to 200,000 miles
Symptoms owners cite: Stall at traffic light or complete stop; Stall while reversing or shifting gears; Stall during slow-speed turn from stop position; RPM drops and vehicle turns off independently; Vehicle restarts after several attempts, sometimes stalls again immediately; No warning light (on some occasions) or check engine light illuminated
Codes mentioned: P1450 (fuel system pressure), P0456 (EVAP leak)
Repairs/costs cited: Purge valve replacement performed on multiple vehicles but failures recurred. Fuel pump and fuel tank replacements recommended by mechanics. One vehicle's transmission control switch replaced without resolving stalling; clutch and transmission later identified as needing replacement. PCM software updates attempted without success.
Recalls/TSBs owners mention: NHTSA Campaign 19V515000 and 18V735000 provide PCM and software updates. Purge valve replacement recommended but only if VIN is included in recall and parts are available. Many VINs reported as not included in recalls despite owners matching recall criteria.
Inaccurate transmission warning/TCM issues
Transmission warning message displayed on instrument cluster; transmission control module (TCM) or powertrain control module (PCM) malfunction or software crash.
When: Reported at 52,000 to 130,000 miles
Symptoms owners cite: Transmission warning message displayed; Vehicle fails to start with transmission warning illuminated; PCM software crash diagnosed; Unknown transmission switch failure causing stall on shift; Dual clutch transmission shuddering and gears shifting incorrectly
Codes mentioned:
Repairs/costs cited: PCM software updates performed; transmission control module reprogramming attempted. Transmission computer module replacement, clutch replacement, and transmission replacement recommended on different vehicles. Costs not detailed by owners.
Recalls/TSBs owners mention: NHTSA Campaign 19V515000 includes PCM software updates. Campaign 18V735000 may include software update. One owner's VIN not included despite matching symptoms. Repair cost and availability of parts remain issues.
Synthesized from 53 NHTSA owner complaints — unverified consumer
allegations, summarized for patterns. The verbatim filings appear below.