Ford Explorer Fuel System Problems

Fuel System complaints by model year

Which parts fail

• Delivery › Fuel pump
  44
• Delivery › Hoses, lines/piping, and fittings
  39
• Fuel injection system
  31
• Storage › Tank assembly
  26
• Delivery
  17
• Storage › Fuel gauge system
  17
• Carburetor system
  16
• Storage › Tank assembly › Filler pipe and cap
  8

Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).

Mileage when the problem started

• Under 25k
  22934%
• 25k–50k
  13520%
• 50k–75k
  13420%
• 75k–100k
  8513%
• 100k–150k
  639%
• 150k+
  345%

What owners report

On several occasions when trying to drive from a stopped position I press the gas and the car will move slowly but not shift into gear and then after turning off it struggles to restart. The check engine light is solid but goes away by the next day. This has happened after sitting idling in a parking lot most often but recently it happened 2 times as I was turning left onto a street where I luckily was able to slow roll to the side and not get hit. I brought it in once for service and they struggled to find the issue for hours and eventually said pins in the fuel injector were lose and replaced but it is continuing to randomly happen.

I purchased this new car from Bell Ford on [redacted]. Since I have owned it, it has been under Ford's care for almost 2 weeks at 2 different service departments. (I have owned for 90 days.) The car sputters and stops when putting on the gas from a start position. I ended up stalling in a busy intersection on [redacted] All the dash lights come on and then the engine light comes on. Says, take to dealer. They are replacing the fuel pump now and trying that. This car has less than 4900 miles on it. The car they have given me to use is not comparable.

Car was parked on a driveway, decent grade, with 50 miles left to empty (no low fuel light on). Facing downward. Car did not turn over. Had to use manual override to put vehicle into neutral and coast to a more level area and start it up. Seen this issue posted on the Explorer ST Facebook group multiple times, so I was lucky I knew what the issue is. Most other people would be stranded. There is a flaw in the Explorer's fuel tank system that will not allow the car to start if fuel level gets below a certain threshold when parked facing down a steep street or driveway.

I am reporting a severe safety hazard regarding an immediate, drastic increase in fuel consumption and erratic fuel range calculations following a manufacturer recall repair. My 2025 Ford Explorer ST-Line was operating perfectly until a Ford Mobile Service technician performed safety recall 26S21 (IPMA Reset). According to official Ford manufacturer specifications, this SUV has an expected driving range of up to 501 miles on a full 17.9-gallon tank of fuel. However, immediately following this software update, the vehicle's total driving range drastically dropped. On a 100% full tank of gasoline, the dashboard's "Distance to Empty" (DTE) display now only reads 316 miles left to empty-nearly 200 miles below the manufacturer's expected capability. …

The contact owns a 2023 Ford Explorer. The contact stated while driving 75 MPH on the interstate, the vehicle lost motive power. The contact stated that while depressing the accelerator pedal, the vehicle responded as intended. No warning light was illuminated. A dealer was contacted. The vehicle was taken to a dealer however, the dealer was unable to retrieve a diagnostic trouble code, and informed the contact that there was no failure. No assistance was provided. The vehicle was not repaired. The manufacturer was notified of the failure, and informed the contact that the repair would have to be out-of-pocket with the possibility of being reimbursed. The contact related the failure to NHTSA Campaign Number: 25V455000 (FUEL SYSTEM, GASOLINE); however, the VIN was not included in the recall. The contact was referred to the NHTSA Hotline for assistance. The failure mileage was 17,000.

I have had 4 Ford Explorers that have the same problem that Ford has not commented on when I complain. If the car is parked facing down a hill with less than 1/4 tank of gas it won't start. The design of the tank precludes gas from reaching the engine. Unable to start the car, it cannot be brought out of park and rolled to a flat location. This time I had more than 1/4 of a tank and the same problem occurred. This happened in my driveway but what if you're on a street with an incline?

The contact owns a 2022 FORD EXPLORER. The contact received notification of NHTSA Campaign Number: 25V455000 (FUEL SYSTEM, GASOLINE) however, the part to do the recall repair was not yet available. Local dealer was contacted. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The contact state that while his daughter was at a stop sign and depressing the accelerator pedal to drive, the vehicle stalled. The contact was concerned that control of the vehicle was lost and could result in a accident. In addition, the contact stated that when depressing the brake pedal there was an abnormal sound coming from the vehicle. The failure would occur on numerous occasions. The vehicle was taken to a dealer where it was diagnosed but the failure was not determined. The vehicle was not repaired. The manufacturer was notified of the failure. …

The contact owns a 2022 Ford Explorer. The contact stated that while his wife was driving 10 MPH with children inside the vehicle, while depressing the accelerator pedal, the vehicle hesitated and loss power. While attempting to restart the vehicle, the vehicle failed to respond. A dealer was contacted. No warning light was illuminated. The vehicle was towed to a dealer where it was diagnosed and determined that the fuel pump needed to be replaced. The vehicle was not repaired. The contact associated the failure with NHTSA Campaign Number: 25V455000 (FUEL SYSTEM, GASOLINE); however, the VIN was not included in the recall. The vehicle was repaired. The contact stated that the failure had occurred on several occasions. The manufacturer was notified of the failure and informed the contact that a representative would return the phone call. The approximate failure mileage was 66,000.

Related recalls (12)

NHTSA investigations