2003 Ford F-150 Fuel System Problems

Which parts fail

• Storage › Tank assembly
  1
• Fuel injection system › Fuel rail
  1
• Delivery › Hoses, lines/piping, and fittings
  1
• Storage › Tank assembly › Mounting
  1

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

Mileage when the problem started

• Under 25k
  25%
• 25k–50k
  514%
• 50k–75k
  25%
• 75k–100k
  38%
• 100k–150k
  1438%
• 150k+
  1130%

Owner reports

Selected complaints filed with NHTSA by 2003 Ford F-150 owners, lightly cleaned up (personal details are redacted by NHTSA).

I purchased this F150 in November, 2023. The only code shown was a lean code, P0171. I removed the bed first to begin my inspection. Upon removing the original fuel tank, I discovered a gash in the top of the tank,about 1/8" wide by 3" long. It should have set a code like a missing gas cap would, but there was none. The gash appeared to be several years old due to the rust pitting. I believe the gash was a result of the cross member rubbing against the tank. The previous owner did not mention the defect. Fuel would have spilled out if the tank was completely filled. I did not find any service alerts for this though they may exist. The truck currently has 225k miles.

The contact owns a 2003 Ford F-150. The contact received notification of NHTSA Campaign Number: 11V385000 (Fuel System, Gasoline) however, the part to do the recall repair was unavailable. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had not experienced a failure. Parts distribution disconnect.

Tl* the contact owns a 2003 Ford f-150. The contact stated that the check engine warning light had been illuminated since the day of purchase. The contact also stated that while the vehicle was parked in the car port the vehicle suddenly caught on fire. The fire department came and put out the fire. A fire department report was made. The vehicle was deemed totaled as well as damaged the contact's residence. There were no injuries. The contact contacted a certified mechanic who informed them of a recall for the year/make/model, NHTSA campaign number: 06e056000 (fuel system, gasoline). The contact stated the VIN had not shown to be included in the recall. The manufacturer was not made aware of the failure. The approximate failure mileage was 203,000.

I drove the truck about 90 miles Sunday July 29. Parked the truck in front of my home went inside and about 10 minutes later heard an explosion. Went out front and found my truck engine compartment fully engulfed in flames. Fire was so hot it melted engineer parts and the hood. I had checked the oil, coolant and trans prior to making the trip. There were no leaks of any type. Have never had any issues with fule or oil leaks.

My 2003 f150 had the straps holding the gas tank snapped while traveling down the interstate at 65 MPH, I could see flames on the road from the fuel leaking when the tank hit the highway. Once I stopped the truck, I found the gas tank had fallen off and was dragging the ground leaking fuel everywhere, I had 20 gallons of fuel leak out so I had to call the bristol, va fire dept. To come clean up the fuel spill, there was no damage to the truck other than the fuel tank and the straps that I know of needing to be replaced. The local Ford dealer tells me that Ford has a recall on this in areas of the country, but not in virginia. …

Tl* the contact owns a 2003 Ford f-150. The contact stated that while driving at an unknown speed, the fuel tank strap fractured and the fuel tank drop to the ground. The vehicle was taken to the dealer. The technician confirmed that both fuel tank straps fractured due to corrosion and as a result, the fuel tank needed to be replaced. The technician made the contact aware that the vehicle was not included in NHTSA campaign number: 11V385000 (fuel system, gasoline). The manufacturer was not made aware of the failure. The vehicle was not repaired. The failure mileage was 160,000.

Tl* the contact owns a 2003 Ford f-150. The contact stated that the fuel tank strap fractured and caused the fuel tank to separate from the vehicle. The fuel tank was punctured. The contact stated that there was evidence of a fuel leak underneath the vehicle. The contact was concerned that the punctured fuel tank was a fire hazard. The vehicle was not diagnosed or repaired. The vehicle was included in NHTSA campaign number: 11V385000 (fuel system, gasoline). The manufacturer was notified of the failure. The approximate failure mileage was 120,000.

Tl* the contact owns a 2003 Ford f-150. The contact stated that the fuel tank failed. While driving 10 MPH, the vehicle emitted a popping noise. The contact was able to coast onto the shoulder, inspected the vehicle, and found that the fuel tank separated from the strap due to corrosion. The vehicle was towed to the contact's home. The dealer stated that the vehicle was not included in NHTSA campaign number: 11V385000 (fuel system, gasoline). The vehicle was not repaired. The manufacturer was not notified. The failure mileage was 100,000.

In March of 2014, my fuel tank straps broke due to excessive corrosion and my fuel tank fell to the road while I was driving. I paid to have it repaired that same month but I recently learned that this problem was in a Ford recall, campaign number 11s21. I took the bill to a local Ford dealership, per the Ford recall instructions, but they denied my claim because I no longer own the vehicle; it was totaled in 2015

While driving my truck with my wife & son, we heard a loud pop, like a gun shot, then my truck started to run real rough, I found a coil, & a spark plug had been blown out of the engine, because of the fuel build up & the spark from the truck still running we are lucky that the truck did not catch fire.

Related recalls

NHTSA investigations

Fuel System complaints in other F-150 years