Other Fuel System Tank Filling/charging problems of the 2011 Ford Explorer

As a repair shop owner, the vehicle owner stated that there was a strong fuel odor after filling the fuel tank. I noticed fuel stains from the top of the tank so I removed the tank and found fuel leaking from the fuel pump module. I found the steel lock ring retaining the module to the plastic fuel tank had rusted and the resulting rust 'bloom' had crushed the plastic flange causing the fuel leak. I have noticed this on another car ( 2007 Dodge grand caravan, VIN 2d4gp44l77r250683) just last week with the same issue. After sharing the pictures with a diagnostic discussion group, others have seen this around the country and canada, especially in the "rust belt" states. This issue seems to apply to any fuel system with a plastic fuel pump module and a steel lock ring in a rust prone area.

When filling the gas tank the gas nozzle would shut off. Even when I was very slowly pumping in gas , the pump would shut off very much like a tank indicating it was full which I know was not the case. Then gas would drip/stream (numerous drips and streams)) under the vehicle creating a basketball size gas spot. Upon service at the dealer I was told the tank vent tube was blocked by cobwebs. Driving for over 50 years , I have never heard of such a thing.