Fuel System complaints by model year
Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
What owners report
On May 4, 2017 I was at a red light on a very busy highway when the vehicle's engine just shut off. Check engine light came on and another wrench symbol light came on. I got it started again but was very slow accelerating and within a few feet it stopped accelerating even when pressing on the gas all the way. I was stuck trying to coast through a very busy intersection until I could get it in a parking lot.it would restart but would not accelerate and then engine was shaking. Then wouldn't start at all. I had to call someone to pick me up and then a tow service to have it towed to a mechanic shop. The repair shop called and informed me that it was running but the check engine light was still on and it gave a computer code for a bad throttle body motor. …
Complete failure of the fuel pump control module (driver) due to exensive corrosion that breached the component housing, leading to electrical shorting that melted the electrical connection terminal. This is clearly an engineering / assembly flaw because corrosion should be anticipated when bolting zinc parts to steel frame members (without a di-electric barrier) installed in an area, subject to direct contact with water & road salt, when being sold in north American climates.
This vehicle continuously just cuts off. We have tried several different costly repairs and the truck still does not run right, it is still cutting off. This is a safety issue because it can happen anytime anywhere, even driving down the road. I spoke with Ford and all they did was open a case file but told me there was nothing that could be done. We purchased this vehicle in December 2014 and was told the only thing wrong with it was that it needed the rotors turned on the brakes which we have done. Then it started doing this. We have had it towed 6 times in about 2 months. 3 mechanics have tried to repair the truck with no luck. We are tapped out trying to fix this truck. I feel sure the guy who sold it to us knew the truck was doing this but opted not to tell us. Also I blame Ford for the problems we are having, even their technician doesn't know how to fix the problem.
I was driving in town and it stalled out. It kept happening at least three times a week even when I was on the freeway. I had far too many close calls from wrecking or causing an accident. I went and had it looked at by a mechanic and he replaced the spring in the fuel reset switch. It is currently in the shop once more for the same problem. My check engine light is also on again. Has been for the last year. It claims there is something wrong with the fuel cap or the fuel lines. I've had a pressure test done and my gas cap changed and it still hasn't fixed the problem. Also my driver side door handle is starting to get stuck and my fuel gauge is no longer registering the actual amount of gas I have. I have so many problems with this truck and I just want them to be fixed. This stuff is dangerous and can cause legitimate accidents and safety issues.
Have had 2 of these 2004 Ford Sport Trac trucks. One which was flipped onto my driver side and totaled in an accident where I was hit doing 25mph down a back road whith a stop sign intersection, no airbags went off the only thing that saved me was my seat belt from worse injures. My current truck which has been well maintained and I still have all receipts for over 5000 worth of work done, recently with over a quarter tank of gas turning left will cut out and die completely in traffic which has almost cause me to be hit a couple times with my child in the car. Also my transmissions went out and lost gears at low mileage. I took my current truck to richards transmission where they told me the Ford Sport track transmission normally doesn't last past 50,000 miles that Ford did not machine the transmission correctly which is a known problem in the Ford Sport Trac. …
Tl* the contact owns a 2004 Ford Explorer Sport Trac. The contact stated that while driving approximately 60 MPH, the vehicle stalled without warning. The failure occurred on numerous occasions. The vehicle was taken to an independent mechanic, who diagnosed that the cam sensor, crank sensor, and the fuel pump needed to be replaced. The repairs were completed by the contact but the failure persistent. The manufacturer was not notified of the failure. The approximately failure mileage was 90,000.
Vehicle will stall after sitting overnight and the engine has not reach normal operating temperature, fuel tank full and the vehicle is proceeding up an incline. When vehicle stalls you can start the vehicle and proceed. After reaching normal operating temperature or the vehicle have travel forty to eighty miles on the tank of gas it will not duplicate the problem until you refill the tank again. If the tank is kept full or no more than one or two gallons are used up. It will not stall. I have had it back for repair five or six times but no luck. The last visit to the dealer they put a recorder on the vehicle which I kept for three weeks and it recorded the stall. The dealer stated that it was being overfilled but I never overfill the vehicle and I explained that to them. I purchase the vehicle new on 7/31/03 and drove it home on the tank of gas the dealer put in it. …
I have had fuel tank issues for a year now and they are getting worse. My gauge stopped working about 13 months ago which was no big deal. Now I am unable to put more then 4-5 gallons of gas in at a time. The safety sensor stops the pump from filling up my tank and if I try to do it a little at a time it just shoots gas out of my fill area and gets everywhere. I have been doused in gas and I have run out of gas in very bad areas. The sensor replacement was only a temporary fix, now it's impossible to put gas in my tank and it's starting to run poorly. I have to stop everyday for gas. This is a malfunctioning Ford part that should be recalled and replaced. I have run out of gas and when that happens every thing shuts down including the power steering. It was dangerous and difficult to maneuver my truck, I was getting on the freeway and the on ramp was a semi-circle.
Frequently asked questions
Which Ford Explorer Sport Trac years have fuel system problems?
By NHTSA complaints, the 2005 (16), 2002 (14), 2003 (11) and 2001 (6) model years. Fuel System complaints make up 24% of all complaints for the 2005.
Is there a recall for Ford Explorer Sport Trac fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for any Ford Explorer Sport Trac model year. A widespread problem may still be covered by an extended warranty or a manufacturer service bulletin, so ask a dealer.
At what mileage do Ford Explorer Sport Trac fuel system problems start?
Across all years, half of the complaints with a recorded mileage happened before about 75,000 miles; 36% happened before 50,000 miles.
What part fails most often?
Owners most often name the delivery (6 mentions), followed by the storage › tank assembly (3).
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.