I've had plenty of Ford in the bay over the years, and the fuel-system complaints on these don't surprise me. 2,624 on the NHTSA record across 155 model-year entries (2005–2024) is not a fluke. The complaints are spread across the lineup — no single model is doing all the work. That tells you it's an engineering or supplier pattern, not a one-off bad year. 36 fire reports on the federal record — not common in this category but documented and worth weight. Average shop fix runs about $1,200 — not catastrophic, but it adds up over time. Across the 1,656 complaints reporting odometer mileage, the median failure lands at about 68,373 miles. Check the fuel pump access cover for prior work. A vehicle on this list that already had a pump replacement is a vehicle to consider — the work is done.
ProblemsByVin FORD / FUEL SYSTEM
155 model-year entries · 2005–2024
Ford fuel system problems
2,624 owner complaints filed with NHTSA against Ford vehicles for fuel system issues. 28 active recall campaigns. See fuel system across all makes →
Complaints
2,624
Recalls
28
Year-models
155
Avg fix
$1,200
29crashes
36fires
21injuries
Worst-affected Ford model-years for fuel system Top 25 by complaint volume
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
2005 Ford Freestyle
106 complaints · ~$1,200 moderate
2020 Ford Escape
100 complaints · ~$1,200 moderate
2006 Ford Freestyle
86 complaints · ~$1,200 moderate
2009 Ford Escape
83 complaints · ~$1,200 moderate
2005 Ford Mustang
77 complaints · ~$1,200 moderate
2010 Ford Escape
69 complaints · ~$1,200 moderate
2016 Ford Focus
58 complaints · ~$1,200 moderate
2017 Ford Focus
57 complaints · 1 recall · ~$1,200 moderate
2022 Ford Escape
55 complaints · ~$1,200 moderate
2018 Ford Focus
54 complaints · 1 recall · ~$1,200 moderate
2013 Ford Focus
53 complaints · ~$1,200 moderate
2005 Ford Explorer
52 complaints · ~$1,200 moderate
2007 Ford Freestyle
51 complaints · ~$1,200 moderate
2021 Ford Bronco Sport
46 complaints · ~$1,200 severe
2005 Ford Expedition
41 complaints · ~$1,200 moderate
2022 Ford Bronco Sport
40 complaints · 2 recalls · ~$1,200 severe
2006 Ford Mustang
39 complaints · ~$1,200 moderate
2005 Ford F-150
39 complaints · ~$1,200 severe
2007 Ford Edge
36 complaints · ~$1,200 moderate
2021 Ford Escape
35 complaints · ~$1,200 severe
2012 Ford F-150
35 complaints · ~$1,200 moderate
2005 Ford Ranger
34 complaints · ~$1,200 severe
2011 Ford Escape
32 complaints · ~$1,200 moderate
2006 Ford F-550
32 complaints · ~$1,200 moderate
2006 Ford F-150
30 complaints · ~$1,200 severe
Active recalls — Ford fuel system 12 on file
Roush is recalling certain model year 2009-2011 Ford e-150, e-250, and e-350 5
A propane leak in the presence of an ignition source can result in a fire.
Fix: Roush will notify owners of the vehicles of which the kits were installed in order to arrange for free replacement of the injector retention clips. The safety recall began on september 26, 2011. Owners may contact roush at 1-734-466-6255.
Roush is recalling certain aftermarket roush clean tech liquid propane autogas fuel system kits used for installation on the following vehicles: model year 2007 and 2008 Ford e-350 (duel rear wheel), my 2009-2011 Ford e- 150, e-250, and e-350, and my 2009-2011 Ford e-450 cutaways
A gas leak in the presence of an ignition source can result in a fire.
Fix: Roush will notify owners of the vehicles of which the kits were installed on in order to arrange for free replacement of the injector retention clips. The safety recall began on september 29, 2011. Owners may contact roush at 1-800-59-rouch (1-800-597-6874.
Ford is recalling certain model year 2013 Explorer, Taurus, Flex, Fusion, Police Interceptor Sedan and Police Interceptor Utility vehicles; and certain model year 2013 Lincoln MKS, MKT, and MKZ vehicles
A fuel leak in the presence of an ignition source may result in a fire.
Fix: Ford will notify owners, and dealers will replace the fuel delivery module, free of charge. The recall began on July 20, 2013. Owners may contact Ford Motor Company Customer Relationship Center at 1-866-436-7332. Ford's recall campaign number is 13S04.
Roush performance products is recalling certain 2011 Ford e-series vans equipped with 5
A propane leak in the presence of an ignition source may result in a vehicle fire.
Fix: Roush will replace the defective valve with a correctly machined one. All the affected vehicles have been repaired, therefore, an owner notification letter will not be issued for this campaign. Owners may contact roush at 1-734-466-6255.
Roush is recalling certain aftermarket roush clean tech liquid propane autogas fuel system kits produced between december 17, 2010, and may 6, 2011, used for installation on fleet vehicles model year 2009 through 2011 Ford e-series vans/wagons/shuttles/cutaway (150, 250 and 350) with 5
A gas leak in the presence of an ignition source can result in a fire.
Fix: As of may 27, 2011, roush had notified all owners of record by telephone and shipped to them replacement valves free of charge. Owners may contact roush at 1-734-466-6255.
Ford Motor Company (Ford) is recalling certain model year 2007-2008 Lincoln MKX, and Ford Edge vehicles, manufactured June 15, 2006, to September 22, 2008, and originally sold, or currently registered in, Connecticut, Delaware, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin and the District of Columbia
A fuel leak in the presence of an ignition source increases the risk of a fire.
Fix: Interim notices were mailed to owners on December 12, 2014. The recall began on October 6, 2015. Dealers will inspect the vehicles and either clean and treat the fuel tank with a corrosion preventative or replace the tank, free of charge. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 14S22.
Ford Motor Company (Ford) is recalling certain model year 2015 Ford Taurus, Lincoln MKS, and 2016 Ford Explorer vehicles manufactured on July 24, 2015
If the fuel tank separates from the vehicle, a fuel leak may occur, increasing the risk of a fire.
Fix: Ford will notify owners, and dealers will tighten the fuel tank attachment bolts, as necessary, free of charge. The recall began on October 19, 2015. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 15S26.
On certain trucks built with 26 gallon fuel tanks, the fuel tank may have a depression at the seam between the top and bottom halves of the tank (not visible from outside the fuel tank)
If left uncorrected, a fuel leak could eventually develop. A fuel leak in the presence of an ignition source could result in a fire.
Fix: Dealers will replace the fuel tank free of charge. The recall began on june 25, 2007. Owners may contact Ford at 1-866-436-7332.
Ford Motor Company (Ford) is recalling certain model year 2009-2010 Ford Edge vehicles manufactured September 11, 2008, to July 1, 2010, and Lincoln MKX vehicles manufactured September 23, 2008, to July 1, 2010, originally sold in, or currently registered in, Connecticut, Delaware, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin and the District of Columbia
A fuel leak in the presence of an ignition source increases the risk of a fire.
Fix: Ford will notify owners, and dealers will inspect the vehicles and either clean and treat the fuel tank with a corrosion preventative or replace the tank, free of charge. The recall began on May 10, 2016. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 15S31.
Ford is recalling certain model year 2012 Taurus, Lincoln MKS, and model year 2013 Explorer vehicles manufactured July 19, 2011, through March 15, 2012
A fuel leak in the presence of an ignition source may result in a fire.
Fix: Ford will notify owners, and dealers will inspect the fuel tanks and replace them as necessary, free of charge. The recall began on May 9, 2013. Ford's recall campaign number is 13S03. Owners may contact Ford Motor Company Customer Relationship Center at 1-866-436-7332.
Ford Motor Company (Ford) is recalling certain model year 2010-2012 Ford Escape vehicles manufactured February 26, 2009, to April 29, 2012, and 2010-2011 Mercury Mariner vehicles manufactured February 25, 2009, to December 12, 2010
A fuel leak in the presence of an ignition source increases the risk of a fire.
Fix: Ford will notify owners, and dealers will replace the FDM flange with one that has a redesigned fuel supply port, free of charge. Remedy parts are currently unavailable. Interim notices were mailed to owners on December 13, 2016. Owners will receive a second notice when remedy parts become available. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 16S41.
Ford Motor Company (Ford) is recalling certain model year 2013 Escape vehicles manufactured from October 5, 2011, through July 11, 2012, and equipped with a 1
A fuel leak in the presence of an ignition source may result in a fire.
Fix: Ford will notify owners and dealers will inspect the engine compartment fuel line, and if necessary, replace it, free of charge. An interim notice will be mailed to owners during January 2014. The recall began on April 9, 2014. Owners may contact Ford at 1-866-436-7332. Ford's recall number is 13S12.
Common questions
How many Ford fuel system complaints are on file with NHTSA?
2,624 complaints across 155 model-year entries from 2005 to 2024. 28 active recall campaigns cover fuel system issues across the Ford lineup.
Which Ford model has the most fuel system complaints?
The 2005 Ford Freestyle leads with 106 complaints in this category. Next: 2020 Escape (100) and 2006 Freestyle (86).
What does it cost to fix Ford fuel system problems?
Independent shops average $1,200 for fuel system repairs across the Ford lineup. Dealer pricing tends to run twenty to forty percent higher. Specific cost depends on the failure mode and parts availability.
Are there Ford fuel system recalls?
Yes — 12 active recall campaigns cover fuel system on Ford vehicles. Recall fixes are free regardless of mileage or warranty status. The list below shows current campaigns with their NHTSA numbers.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA) public records database.
Editorial commentary written by Mark Driver, an independent contributor to ProblemsByVin
and not affiliated with Ford.
Severity ratings derive from reported crashes, fires, injuries, and fatalities on the NHTSA complaint and recall record.
Repair cost averages reflect independent-shop pricing and may differ in your area.