Other Fuel System Tank Assembly problems of the 2009 Ford Flex

As has been reported many time on here and in the Flex forums, the vehicle will suddenly stall at a 1/4 tank of gas for no reason. I was traveling down the interstate at high way speed when the fuel gauge dropped to e and the miles to empty read 0. This has happened three times. I called one of my local dealers who insisted they have never heard of this problem and nothing was done. There advice was to not let the car get to a 1/4 of a tank. They have no fix for this dangerous problem.

Fuel gauge reading drops suddenly from 1/4 tank to empty in a matter of seconds, not allowing time to get out of traffic. Happened numerous times but so far only when the vehicle has been in a position to pull off the road (on single lane roadway, or in the right hand lane. Has beed at highway speeds, and on residential area.

Engine stalls despite fuel gauge reading 1/4 tank in reserve. Fill up confirms that there is in fact 1/4 tank left. Has happened several times now.

Gas gauge will read between 14 to 1/2 tank of fuel then without warning drops to e and car dies. Faulty fuel sensor or pump due to saddlebag tank design. Also no cutout in floorboard to access the secondary sensor or pump. There is still about 4 or 5 gallons of fuel in the tank but the car thinks it is empty.

Car said '15 miles to empty' and gauge needle was just below a quarter, then needle dropped to empty and computer estimate went down to '3 miles to empty' within a mile. . Then shut down and limped off road. Left me stranded on the side of a busy city freeway in a very dangerous location, until I could get someone to bring gas to refuel. Repeated this the next time the gas was down to a quarter tank. I watched it carefully and saw it recalculate from approx 15 to empty, to 0 in less than 4 miles. Got to a gas station in time before the car shut off. Now I fill it up at 50 miles until empty to avoid running into this issue. . Read more...

The issue that has recently cropped up on our Flex is the fuel meter will read sufficient fuel for approximately 50 miles and then, in a matter of miles, the tank seems to run dry/indicate no miles left. On this particular date I was driving the car it indicated 49 miles to empty. After 3 miles it ran out of gas. Fortunately I was on a side street and not the highway. This behavior could have been fatal if I was operating on a highway. I am not the only one having this issue. Please see Fordflex. . Read more...

Vehicle does not recognize last quarter tank of fuel. Once it reaches approximately a quarter tank left, the fuel gauge and miles to empty display drop suddenly to empty and the car shuts off. When refueling after it shows empty, it only accepts about 3/4 tank. The fuel is there, but inaccessible. This is a major safety issue as the car dies very suddenly when the system decides there's no fuel left. It has happened on the interstate, other highways, and on a rural road where finding enough fuel to get going again was a big problem. Dealership replaced fuel sensors, but said there was no code showing while the car was still under warranty. Now I'm stuck randomly replacing fuel system pieces in hopes of figuring out which piece is broken. Each time I spend hundreds of dollars to "fix" it, the problem repeats as soon as I get through most of the first tank of fuel. Position of vehicle doesn't matter. Uphill, downhill, etc, it always happens close to a quarter tank of fuel left.