Tank Assembly Problems of Ford Windstar - part 1

After filling the vehicle fuel tank at the fullerton MD bj's warehouse store, gasoline began spilling from the underside of the vehicle onto the pavement. The baltimore county fire department (bcfd) was called to the scene and responded with three pieces of equipment. Bcfd applied absorbent to the spilled fuel and contained it until they could transfer the fuel (approx. 25 gals) from my vehicle's tank into a safe storage container. After they completed that service, the vehicle was towed to the local Ford dealership, bob davidson Ford, for diagnosis and repair. The vehicle tank had developed a structural crack in its wall approx. 3 inches long ("hairline") in the same location already designated the documentation described by NHTSA recall number 99v309 / Ford recall no. 99s33, immediately above the center left tank support strap. I can produce clear photos of the crack. I require assistance from the NHTSA in recovering the $1,660. 01 I paid the Ford dealer on 10/9/12 for the repair of the tank (they could only find a used tank to install) for what is obviously a manufacturer's defect. As of this date, 8 days later, the used "new" tank has also begun to leak. Many thanks.

The vehicle had a fuel leak at the fuel tank. I removed the tank to see that the tank looked like it was pinched and developed a crack. The fuel tank is plastic so I found this to be odd. I had to put epoxy on the tank to patch the crack so I could get it home as I was out of town when this happened. When I got home I started looking online for a tank and found that Ford had a recall on this matter. I called lafayette Ford and explained the recall and gave my VIN #. I was told that tmy vehicle does not fall under the recall that I will have to repair it myself. If I have the same vehicle of the recall and the same problem of the recall why does Ford not honor it. The recall states the crack at the front strap area and that Ford will replace the tank and the strap with a longer one and a bushing. My tank has the crack at the front strap and the tank was pinched because the strap is too short.

See all problems of the 1996 Ford Windstar 🔎.

The contact owns a 1996 Ford Windstar. While the vehicle was parked, the contact noticed an excessive amount of gasoline on the ground. The vehicle was taken to a local repair facility where the independent mechanic located the failure as a fracture in the fuel tank. The vehicle was not repaired. The failure mileage was 200,000 and the current mileage was 212,902.

1996 Ford Windstar fuel tank has a crack in it and is leaking fuel I see the recall only effaced 1995 Windstars but apparently the problem was not fixed on the 1996 Windstars because mine has a 3 inch crack in it. I do not know if some of the 1996 Windstars were in this recall.

While the van was park, I notice a strong smell of gasoline. I took it in to my auto repair shop to be fixed. The shop found a crack in fuel tank that was not the results of impact damage.

I have Ford Windstar,96. When I filled up gas in the tank,it started leaking and is continuously leaking. It seems that it is leaking from the tank.

: the contact stated there was an odor of fuel in his garage. The vehicle was taken to the dealership, but a determination was not given. There is a NHTSA recall, # 99v309000, regarding the tank assembly; however, it is not included in the recall due to the VIN. Updated 5/30/2006 - the consumer inspected the vehicle and found that the fuel tank was leaking at the strap on the driver's side. The tank began to leak where the manufacturer has apparently over-tightened the support straps for the tank. The 1995 model was recalled (99v-309000), manufacturer number 99r33 regarding the exact same issue. The consumer contacted the dealer but they provided no assistance. Updated 06/27/06.

The 1996 Ford Windstar has a fuel tank on it that is identical to the 1995 Ford Windstar. The 1995 was recalled for a leak on the upper portion of the tank. The 1996 version was not recalled. My 1996 leaks same place as the 1995 recalled version. Dangerous fuel can seep down tank and drip on exhaust system or other components to cause fire or explosion. Ford does not want to replace tank on 1996. Nothing was done by Ford to correct this problem.

The contact owns a 1996 Ford Windstar. Vehicle had a crack in top of fuel tank, also at strap. Recalls on 1995 Ford Windstars pertained to the make of vehicle. S melled gas fumes and gas tank register was noticeably different. Smelled gas fumes while parked in driveway or while driving . Incident happened September 25, 2005. No crash . No police report. Updated 1/25/2006 -.

Consumer stated excessive fuel was leaking . Dealer indicated that top of the fuel tank broke apart.

See all problems of the 1998 Ford Windstar 🔎.

Gas tank leak. I leave in one of the states that is listed in recall 99v309000 that states hot weather increases cracks in fuel tanks on 1995 Ford Windstars. My vehicle is a 1996 with a build date of 10-02-1995. Ford motor will not consider this vehicle for replacement. They need to re-evaluate the recall to include a wider range than they now have. I was told by the dealership that my leak looks just like a 1995 they fixed on 07-23-2004. Please help on this safety issue.

Fuel tank collapse on 1998 Windstar dealer wants $1300 dollars to replace fuel tank and all related components. Dealer says this is because there is a vacuum inside tank created by the fuel pump. Perfectly running van that has been kept up maintenance wise is now inoperative do to stalling.

Everytime I feel my gas tank up it spits gas out at me. I cringe at the thought of pumping gas. I let it go pretty low before resorting to a gas shower. As soon as I start pumping (s l o w l y) it will start immediately. There's more gas on the ground then in my tank! so pathetic!.

See all problems of the 2002 Ford Windstar 🔎.

Ford installed improper size fuel tanks which caused the wire in the fuel tank to chafe and short out which caused the vehicle to stop running. The consumer believes the manufacturer should be financially responsible for repairing the problem.

Fuel tank collapsed. As a result, the 22 gallon tank can only take in 13 gallons.

The vehicle developed a serious gasoline leak. The dealer states that the gas tank is plastic and has cracked causing the leak.

Fuel tank broken / punctured when ran over on a unknown object (suspect tire piece) during night on a rainy day.

1998 Ford Windstar. According to dealer repair dept there was a hole in the fuel tank caused by corrosion relating to the emission tubing. Had to replace fuel tank. Reported to Ford, they have nothing to report. Dealer person said they have replaced several of these and this is in a small rural town. Tank was back ordered for a month. I would think that a hole in a gasoline tank would be hazardous, and given the statement of seeing several of these in one dealership plus the backorder situation indicates this is a widespread problem.

our fuel pump went for a second time in a three month period. The cause of the fuel pumps malfunction was a short in the wiring which was caused by the fact that the depth of the fuel tank was not within the required specifications. The depth of the fuel tank was only 6 5/8" deep. If the depth of the tank is to shallow, the wiring atop the fuel pump can become chaffed on the metal fuel hose clamp. Ford had issued a service bulletin on this very issue. What occurred with our van was precisely what the service bulletin warns of. The service bulletin states that if thefuel tank depth is less than 7 3/4" replace the fuel tank 9002 and fuel delivery module 9h307.  our van clearly met that criteria, however, Ford would not replace the fuel pump or fuel tank at Fords expense. The service manager and technician at Ford stated that if I were a regular customer of duddie Ford, that they would not let me take the van with me because of the safetyissues involved. When I asked what exactly they meant, they stated that because of the chaffing of the wiring on the fuel pump, a short could occur, which could ignite gasoline fumes and therefore result in a catastrophic tragedy. Basically, the van could explode. An appointment was made at granite Ford in rochester, new hampshire for replacement of the fuel tank per the service bulletin. The granite Ford technician also measured the depth of the fuel tank and found a depth of only 6 5/8". (see granite Ford invoice) the fuel tank was removed and replaced. Dt.

A crack has developed in the gas tank, causing a leak.

Fuel tank leaking. . Dealer was not notified at this time. Feel free to provide any further information.

This is the second time I have had the van in because the check engine light came on. The first time they told me it was a faulty sensor but now they say it is a cracked seal in the fuel tank. When I asked the part's guy when I could expect the part in he told me that there was a "national backorder" on the fuel tank because Ford has had to replace a lot of them.

See all problems of the 2001 Ford Windstar 🔎.

Engine stalled; reported to sheehy Ford; replaced sensor; within a week vehicle stalled again and often. Reported to dealer; could not duplicate stall condition. Stalling occurred up to 13 times a day; returned vehicle to dealer. After two days dealer found that plastic gas tank had collapsed, causing a vapor lock, affecting fuel flow to engine and resulting in stalls. Gas tank replaced at cost of $882.

Fuel clapsed while on vacation blowing fuses and ruining fuel pump had to have both replaced. Ford claimes has had no other problems with this.

After filling at gas station, noticed fuel leaking from top portion of tank. Had tank replaced at local shop. Cost of tank $250 plus labor and misc. Parts.

Consumer had three quarters of fuel nside of vehicle. Next morning he went outside to start vehicle and it woud not start. Dealership was aware of problem.

See all problems of the 2000 Ford Windstar 🔎.

This form was filled out two days ago and I couldn't get the form to do what I wanted. The first report on this vehicle involved a craked ceramic fitting at the top of the gas tank. This report involves a sudden and rapid loss of fuel to which the fire department said could have resulted in a fire and a subsequent explosion. Please refer to my report of two days ago. Thank you.

20 gallon tank has cracks in it. Fuel is leaking all over the ground. Consumer has taken vehicle into dealer. Please provide any further information.

Fuel tank leak, may have caused extensive fire.

This vehicle was serviced on 7/12 and on the way home the engine light came on. I contacted the dealer and took the vehicle in for correction. Finally determined that a ceramic plug at the top of the gas tank had cracked. Needed to replace entire tank and it was. Two weeks later driving and a big time gas leak developed-fire dept called and vehicle towed for repair. Fire department stated that we were lucky that there was not a fire and ensuing explosion. There was another Windstar at the dealer at the same time with the same problem.

After the fuel tank was replaced we inquired of the mechanic if the tank cracked due to misuse. The machanic could not see any signs of misuse, the tank was properly mounted and the crack was on the upper portion of the tank. We noticed ont he news recently a recall for Ford econoline vans from the same period were being recalled due to cracked gas tanks. Does Ford use the same gas tank on the Windstar? has anyone else complained of this problem?.

Gasoline tank was building up pressure inside of tank. When he opened gasoline tank cap there was a sound like explosion . When fuel was inside, there was pressure. Dealership was aware of problem mechanic replaced fuel pressure tank valve.

Intermittent problem with fuel gauge not working properly. Gauge would remain on empty side. Vehicle been in dealer shop, and was unable to locate problem because gauge was working at that time. Feel free to provide any further details on this matter.

See all problems of the 1999 Ford Windstar 🔎.

Fuelwas escaping from tank and fumes getting inside of vehicle. Dealer had been contacted.

While putting fuel into the fuel tank, the cabin fills with fuel odors, the odor is very strong and stays for about 4 or 5 minutes, the odor makes the consumers sick, so they are requesting a refund or replacement because the dealer has failed several times to correct the problem.