2020 Ford Explorer Fuel System Problems

The contact owns a 2020 Ford Explorer. The contact stated that while driving at an undisclosed speed, the vehicle lost motive power. There was no warning light illuminated. The vehicle was inspected using a scanner and provided an error code for the fuel pump module. The vehicle was towed to an independent mechanic, where it was diagnosed and determined that the high-pressure fuel pump had failed and needed to be replaced. The vehicle was not repaired. The dealer was contacted. The vehicle was not diagnosed or repaired. The manufacturer was made aware of the failure and referred the contact to the NHTSA Hotline further assistance. The failure mileage was approximately 112,000.

There is hesitation when coming from a stop to accelerating there is a delay of power. This problem has been going on since we have had the car. It is safety issue especially when we accelerate to get onto the highway. It is very inconsistent. We recently took it in and found that an error code of P0496 the evaporator purge valve to be a problem. Not sure if this is a problem with other Fords like ours. So I thought you could investigate it for me. Thank you.

Fuel does not pump in correctly and causes spit back. The car has been taken into ford numerous times without a solution & parts have been replaced. The problem still exists. This causes gas to leak at the gas station as it doesn’t flow fast into the tank even on the lowest flow possible. You are also unable to move the nozzles around, in or out to make it work.

The contact owns a 2020 Ford Explorer. The contact stated that while driving at various speeds, the contact became aware of an abnormal fuel odor inside the vehicle. There were no warning lights illuminated. The vehicle was inspected by a relative who became aware that one of the fuel hoses was fractured. A local dealer was contacted; however, the vehicle was not repaired due to the cost. The manufacturer was made aware of the failure and referred contact to the NHTSA Hotline for assistance. The failure mileage was approximately 54,000.

Muffler tailpipe separated at the wield of the muffler

Adding gas to my FORD EXPLORER 2020 Limited EcoBoost 4WD, is almost impossible. We just purchased this vehicle used in November 2023. No matter what gas station we use, no matter how slow we fill, the nozzle continuously clicks off every few seconds. We use the funnel that came with the vehicle & the gasoline consistently spills out along the side of the vehicle. The only way to get gas in the tank is with the funnel at the slowest fill possible. When the tank is on the fuller side, it sloshes around incredibly loud & there’s also a knocking sound on the driver side under the steering wheel area. I’ve looked online & have seen so many others that have these same issues. Took the car back to the dealership, they attempted to fill up the tank themselves and were just as confused as I was on how difficult it was to fill the tank.

Fuel gauge on electronic instrument panel shows empty at all times. Driver can run out of gas without warning. Vehicle OBDC shows fuel sensor fault, local dealer claims a faulty instrument cluster with very costly repair. No warnings before this happened. Just Fuel light coming on, check engine light coming on and fuel level showing Zero.

There have been a few times when the gas pedal (accelerator) isn’t responsive. I have pressed the accelerator to the floor a few times and there has been a long delay in response from the engine and when it did respond it was at a lower rpm then expected when the pedal is to the floor. It has occurred when the vehicle is at a stop and the accelerator is pressed to hard. This has occurred multiple times.

WHEN STOPPING, MOVING SLOW OR PULLING INTO A PARKING SPOT OR GARAGE YOU CAN HEAR AND FEEL THE FUEL IN THE TANK SLOSHING BACK AND FORTH. THIS HAPPENS WHEN THE FUEL TANK IS AT LEAST 1/2 FULL AND IS VERY NOTICEABLE BUT SEEMS TO GO AWAY WHEN FUEL IS UNDER 1/2 TANK.

WHEN PARKING VEHICLE OR BACKING OUT OF GARAGE SLOWLY, YOU HEAR FUEL SLOSHING UNDER THE FRONT SEATS LIKE THERE IS NO BAFFLE IN THE TANK. VERY VERY NOTICEABLE AND ALSO MENTIONED ON THIS SITE FROM OTHER FORD OWNERS. A TSB SHOULD BE ISSUED BY FORD IMMEDIATELY AS THEY DID FOR THE SAME ISSUE WITH TSB 18-2378. THIS IS NOT A NORMAL CONDITION AND IT'S A COP OUT FOR FORD NOT TO ADDRESS THIS PROBLEM THAT THEY HAVE HAD IN OTHER FORD PRODUCTS AND THIS ONE NOW AS WELL!!

I TOOK MY CAR TO THE BANK AND PARKED IN THE PARKING LOT AND WHILE I WENT TO THE ATM I LEFT THE CAR RUNNING I WASN'T AWAY FROM THE CAR FOR MORE THEN THREE MINUTES AND WHEN I GOT BACK IN THE CAR IT STARTED SPUTTERING AND THEN JUST SHUT OFF. I TRIED TO START IT BACK UP BUT UPON DOING SO THE VEHICLE WOULDN'T TURN OVER. THE ENGINE SOUNDED LIKE IT WANTED TO TURN OVER BUT WOULDN'T. I TRIED THIS A BUNCH OF TIMES UNTIL THE TOW TRUCK ARRIVED( ABOUT AN HOUR) BUT EVERY TIME THE VEHICLE STILL WOULDN'T TURN OVER. JUST CONTINUED TO MAKE THE ENGINE NOISE THEN WOULD SHUT OFF.

VEHICLE WILL NOT START WHEN PARKED ON DRIVEWAY W/ NOSE FACING STREET IF THERE IS LESS THAN ABOUT A QUARTER OF A TANK OF GAS IN IT. WHEN TRIED TO MANY TIMES THE DASH READS CRANKING LIMIT EXCEEDED. VEHICLE WAS TOWED TO DEALERSHIP - 2021 LOANER WAS PROVIDED AND THE SAME ISSUE HAPPENED. DEALERSHIP ALSO ADVISED THEY HAD ANOTHER CUSTOMER WITH A 2021 EXPLORER HAVE THE SAME ISSUE A WEEK PRIOR. WAS TOLD TO PARK MY CAR IN STREET AND NOT USE DRIVEWAY OR TO ALWAYS HAVE MORE THAN A QUARTER TANK OF GAS. THESE ARE NOT ACCEPTABLE ANSWERS

WHEN STARTING AT INTERSECTIONS OR STOPPING YOU CAN HEAR AND FEEL THE FUEL IN THE TANK SLOSHING BACK AND FORTH. I'VE TAKEN MY VEHICLE TO THE DEALERSHIP AND THEY CONFIRMED THE NOISE AND DOCUMENTED IT. THEY REACHED OUT TO FORD WHICH SAID THEY KNEW OF THE ISSUE AND AT THIS TIME THERE IS NO FIX.

FUEL TANK SLOSHING AND CLUNKING NOISE UNDERNEATH THE DRIVER AND PASSENGER SEATS. THE VEHICLE FUEL TANK DESIGN LOCATES A PORTION OF THE GAS TANK UNDER THE VEHICLE AND BELOW THE SEATS. WHEN THE GAS TANK IS ABOVE HALF FULL, YOU CAN HEAR AND FEEL THE GAS MOVING IN THE TANK, ESPECIALLY AT LOW SPEED, DURING TRAFFIC WITH FREQUENT STOPPING. NOT SURE HOW SAFE IS TO FEEL THE GAS MOVING INSIDE THE FUEL TANK AND THE NOISE WHEN THE GAS IMPACTS THE GAS TANK WALLS. WHEN THE TANK IS FULL AND YOU BRAKE, THE FUEL SLOSHES FORWARD AND MOVES SOMETHING INSIDE AND SLAMS AGAINST THE INSIDE OF THE TANK.

DURING LOW SPEED MANEUVERS LIKE PARKING AND WHEN COMING TO A STOP, THE FUEL SLOSHES LOUDLY AND CAN BE HEARD INSIDE THE VEHICLE. IT SLOSHES MOST NOTICEABLY WHEN THE FUEL LEVEL IS ABOVE 3/4 FULL. THE FUEL MOVES SO MUCH IT SOMETIMES SOUNDS LIKE THERE'S SOMETHING HITTING THE FLOOR UNDERNEATH THE DRIVER SEAT OR A DRIVELINE ISSUE.