Other Fuel System Pump problems of the 2009 Ford Flex

Traveling at 70mph the fuel gauge indicated slightly over 1/4 of a tank left and the estimated miles to empty with the mileage-to-empty estimate indicating approximately 70 miles left. Then in under two minutes to when I checked the dash again, the gauge had dropped to zero with the estimator showing 0 as well. Within the next mile the engine ran out of fuel. To fill up the 18. 6 gallon fuel tank it only took approximately 14 gallons at the pump. This indicates that approximately 4. 6 gallons of fuel were still remaining in the tank. Since this model uses a fuel tank design with two sumps the fuel isn't transferring from the one side to the other where the fuel pump is located. This can cause dangerous driving conditions for someone expecting to have one quarter of their fuel tank left.

Traveling at 70mph. Urge fuel gauge indicated slightly over 1/4 of a tank left and the estimated miles to empty with the mileage-to-empty estimate indicating approximately 100 miles left. Then in under two minutes to when I checked the dash again, the gauge had dropped to zero with the estimator showing 0 as well. Within the next mile the engine ran out of fuel. To fill up the 18. 6 gallon fuel tank only took 2. 5 gallons from the jug and another 11. 5 gallons at the pump for a total of 14 gallons. This indicates that approximately 4. 6 gallons of fuel were still remaining in the tank. Since this model uses a fuel tank design with two sumps the fuel isn't transferring from the one side to the other where the fuel pump is located. This can cause dangerous driving conditions for someone expecting to have one quarter of their fuel tank left.

Our 2009 Ford Flex has shut off on 4 occasions while we were driving since Nov. 2013 (11/29/2013, 12/18/2013, 12/28/2013, 4/15/2014). On 3 of the 4 occasions we were on interstate highways (495 in MA, 95 in CT, 81 in PA) which was scary and could have been deadly. On 2 of the 4 shut downs the car would not restart so we had to be towed. We noticed that once the car was taken off the flatbed, it started right up. That tells me that the gas must have moved to where it was needed. On each occurrence the gas gauge read half a tank or just slightly below. The car just shut off which made it difficult to steer. Luckily we were able to coast to the breakdown lane and weren't in speeding, heavy traffic. On 12/21/13 the dealership replaced the throttle body. On 12/28/13 the car shut down again and was towed to the dealership. The fuel sender concern was verified, fuel level was inaccurate, the left hand fuel sender was erratic. They removed the fuel tank, replaced the left fuel sender. On 4/15/14 the car shut down again. The dealership found that the right side of the gas tank was empty while the left side was full. The fuel sender assemblies were removed and the right one was not reading properly. The fuel pump module was also replaced. We do not trust this car and are afraid for the next owner when we trade it in or sell it. Is this a design flaw?.

The car will cut off and think its out of gas. When my car has 1/8 it goes from 50 miles to 0. Then runs out of gas. If I fill up it will say 322 tip empty but only getting 225 out of fill tank of gas. I been having the issue since I purchased car in 2011. The fuel pump sending unit has to be replaced with jet pump.