Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2011 Ford Explorer owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact owns a 2011 Ford Explorer. The contact stated that while driving at an undisclosed speed, the contact detected an abnormal fuel odor. The vehicle was taken to an independent mechanic, who diagnosed that there was a vapor leak coming from the top of the fuel tank. The vehicle was not repaired. The manufacturer was made aware of the failure and advised the contact to file a complaint with the NHTSA Hotline. The failure mileage was approximately 102,000.
The vehicle has been in for service at Downs Ford Dealership twice in the past two years for the same issue and has yet to be resolved. When the gas tank is filled with gas, there is overwhelming smell of gas that doesn't get better until the tank is about half full. The first time the car was in for service, I was told that the gas tank needed to be replaced but they were having trouble finding one. They said to take the car home and they would call when they found one but they never called. The vehicle was brought in a 2nd time to fix the issue in July of 2021. At that time we were told a valve needed to be replaced and charged $500 but it has not fixed the issue. I'm frustrated and tired of wasting $ and time without my car when they don't seem to be able to fix it. Consumer would like to would like to withdraw the complaint.
9/25/22 My 2011 Ford Explorer xlt would start jerking when pushing on the gas paddle and then would start losing speed or power. Today is the third day this has happened so I looked on YouTube and entered my symptoms of my car and it suggested it could be my (electronic position sensor). And YouTube told me there is an extended warranty on this part. I have 140000 miles this vehicle. This vehicle has not been inspected or confirmed by a dealership as of yet. There was no warning when this problem began and no warning lights on the dashboard. I am very hesitant in driving this vehicle around town , fearing it may stop completely.
The fuel sending unit goes bad due to the split tank and differential and drive train have to be taken apart and dropped in order to change. Costing over $1,000.00. You can not go under half a tank of gas and if you do you just run out of gas immediately causing you to stop on highways side roads etc.Its very dangerous to have a vehicle that will just all of a sudden run out of gas and no one is paying to get them fixed because of the pricepoint charged to repair. This is Fords faulty work 1000%
No warning when the fuel relay gasket attached to the pump assembly fails and allows fuel vapor to fill the cabin of the car. Owner safety is at risk of possible fire. I know of 2 Ford dealerships that are aware of the safety hazard.
"2011 Ford Explorer carbon monoxide poisoning concerns recall" accident occurred on May 14, 2019 at houston, texas I slept off while driving and ran into another vehicle who stopped at a stop light waiting for the green light to turn on. I was not able to stop at the stop light because I slept off because of carbon monoxide poisoning. I had no reason to experience such. I was also, constantly smelling fuel coming into my 2011 Ford Explorer. The car I ran into and mine were seriously damaged. The police came and wrote a report on the accident. On two different more occasions, same things happened to me, but luckily I did not run into any other car or damage my car. …
Tl* the contact owns a 2011 Ford Explorer. While driving, the check engine warning indicator illuminated. The vehicle was taken to jones Ford casa grande (1932 n pinal ave, casa grande, az 85122, [phone]) where it was diagnosed that the engine block was mixing with the oil. The vehicle was repaired. On another occasion, the power steering was locking consistently, and the interlock and advancetrac warning indicators illuminated. The failure recurred. The vehicle was taken back to the same dealer and was repaired again. The contact stated that the power assist warning indicator illuminated. The vehicle was towed to the same dealer where the gears and alignment were reset. The contact also mentioned that the check engine warning indicator continued to illuminate. The vehicle was taken back to the same dealer where it was determined that an unknown part needed to be replaced. …
My vehicle produces unbearable smell that gets inside the cabin whenever the RPM reaches 3500 and higher and if the vehicle is in low gear and driving up hill and also when vehicle is idle and you rave up th engine. The smell that gets inside the cabin could make one pass out unless we roll down the windows completely to let a lot of fresh air inside. I went the dealership which I bought the vehicle from the first month and they inspected the car and got back to me that this issue has been already resolved before I had bought the car and its fixed already but its not I've driving the car now for about 5 months and very cautious with it as whenever the incident happens I feel very dizzy by that smell. …
I am not certain where to fully post this or what can happen for this car. I gave this car back to westlie Ford in camas, wa. It was confirmed by a doctor that 3 people got sulfur poisoning from this car. I saw this car instantly back on fords lot even though I had advised them it gave me sulfur poison. When my friend emailed inquiring about the car they advised that the car had not been checked but was a keeper. They car was a lemon from the start and even though I had the car for 7 months it had been in the shop for about 2 months of that time period for different repairs. We also inquired about that with everything on the car fax report. They came back that it was just basic maintenance. 7 issues in 7 months was not basic fixes. The other major thing beside sulfur poison was the car was leaking and had mildew issues before I found the leak. …
As a repair shop owner, the vehicle owner stated that there was a strong fuel odor after filling the fuel tank. I noticed fuel stains from the top of the tank so I removed the tank and found fuel leaking from the fuel pump module. I found the steel lock ring retaining the module to the plastic fuel tank had rusted and the resulting rust 'bloom' had crushed the plastic flange causing the fuel leak. I have noticed this on another car ( 2007 Dodge grand caravan, VIN [redacted]) just last week with the same issue. After sharing the pictures with a diagnostic discussion group, others have seen this around the country and Canada, especially in the "rust belt" states. This issue seems to apply to any fuel system with a plastic fuel pump module and a steel lock ring in a rust prone area.
Fuel System complaints in other Explorer years
Frequently asked questions
How common are fuel system problems on the 2011 Ford Explorer?
NHTSA has 40 complaints about the fuel & propulsion system of the 2011 Ford Explorer, 3% of the model year's 1,197 complaints. The component named most often is storage › tank assembly (1 mentions).
Is there a recall for 2011 Ford Explorer fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2011 Ford Explorer, though it has 6 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2011 Ford Explorer fuel system problems start?
Half of the complaints with a recorded mileage happened before about 50,000 miles, and 22% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 0 fires and 6 injuries to fuel & propulsion system problems on this model year. If you notice symptoms, have the car checked before driving further.
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.