Tank Assembly Problems of Ford Explorer Sport Trac

The contact owns a 2005 Ford explorer. While the contact was adding fuel to the vehicle it sprayed back out. The contact stated that two people attempted to fuel the vehicle and they both experienced the failure. The contact was unable to add fuel to her vehicle and she was also unable to drive it. The fuel gauge on the dashboard displayed that the fuel tank was empty. The vehicle was not taken to the dealer for the failure. The vehicle was not repaired. The approximate failure mileage was 65,806.

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2002 Ford Explorer Sport Trac fuel fill problem. Tank will not fill and spashes out every time I try to get gas covering me with gas and spraying out every where. Forums show this is vary common problem with the sport trac. Vary unsafe.

See all problems of the 2002 Ford Explorer Sport Trac 🔎.

This discrepancy applies to a Explorer Sport Trac new from a dealership in sept 2001. The vehicle "check engine" light illuminated just before the vehicle reached 15,000 miles. The owners manual stated that if the light did not go out after 3 consecutive cold starts to take the vehicle to the dealer. The vehicle was in the window for servicing at its 15,000 mile check-up anyway, so I took it to the dealer and showed them the "check engine" light. I expected the vehicle would be finished with its regular maintenance and the check engine light problem fixed in a day or two. I was wrong, and from reading similar problems reported by other owners, it appears this could be a trend for the sport trac model- if not for the entire explorer genre. The dealer informed me that the fuel pump was leaking and it was what was causing the check engine light to illuminate. Then I remembered that I had often noticed drops of fluid on the driveway each time I backed out. At the time I thought it was condensation from the air conditioning system. I didn't care what it took to fix it because it was covered by the warranty. The dealer had to order a whole new gas tank, because as it was explained to me, the fuel pump was integral to the fuel tank. The fuel tank and pump assembly was not in stock and had to be ordered from the factory. The dealer supplied a rental car while the sport trac was being repaired. It took 2 weeks for the dealer to receive the fuel tank and pump. After they received it, it only took took a couple of hours for the technician to install it and check it out. The vehicle was properly repaired and I no longer see any droplets on the driveway, nor is the check engine light illuminated. Most of the two weeks the vehicle was at the dealership was due to awaiting parts. Any fuel leak should be considered critical for obvious reasons. I asked the dealer's representative if the tank/pump problem was a common problem for the model and they denied it.

The problem is with the design of the fuel tank/vapor recovery system. I was told by the dealer that when the fuel tank is full fuel splashes into the vapor recovery canister and causes the car to stall. There is no fix for the problem. Ford engineers have been contacted and are working on the problem. I was told it would be 60-90 days for a solution. In the meantime I was told to keep the tank 3/4 full or less. The problem is that I was not told of this design problem when I purchased the vehicle. If it is a design problem then every sport trac should be effected. It is a safety problem because the 4 times the vehicle stalled on me three of them were in the middle of a turn. All of a sudden I had no power steering or brakes. Even for myself , a large male, I had trouble completing the turn. I shudder to think bout what would have happened if my 105 pound daughter had been driving the car and it had stalled during a turn. If this is a design problem, then people need to be warned when they purchase the vehicle. Not filling the gas tank completely does work, no stalls occur. Thank you. Tim cole. **dimsii ivoq entry posted after 12/12/02 cut-over to artemis*768014.