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
I had this car repaired twice at a professional mechanic shop that cost me thousands of dollars. Every time, the car comes to stop or dies on me. I replaced the fuel filter one time that is underneath the car. Now the car is sitting in my garage because of the fuel pump not functioning and does not make that sound anymore when you turn the key on.
After driving half-hour in high-way southward on I-45 in the morning. The car cannot be accelerate at around 40mph when I ramp up to 288, and the auto-lock light turned red. Seconds later, it recovered back. 2 minutes later, it happened again . And again . So I parked it . ~8-hours later, I started it and the auto-lock light red again. Seconds later, the engine stopped when I back the car. I stepped on gas-pedal when I tried 3rd time, and the car moved and the auto-lock light kept red. 10-minuts later, when I drive on 288-south at ~60mph, both of the repair light and engine light turned yellow and the auto-lock light off, seconds later, the repair light off. The engine light kept on. So I get down the highway, cannot accelerate car with gas-pedal on and cannot turn sterring wheel, the car slow down and stopped by itself. …
Battery just goes dead over night. Signal lights melted and quit working. Cluster panel just shuts off while running and can't use air, radio, windows, locks, seats, etc. Car shuts off while driving down the road. Have replaced all parts suggested by codes. Still no fix. Wont shift from first gear after cluster panel shuts off. There are hundreds other complaints. This is dangerous and should be an electrical recall. Happens running driving and sitting still.
Electronic throttle body stoppped working. Car abruptly lost all power in busy traffic, lucky to be alive. I was driving in the left lane and all of a sudden all power was gone and the car wouldn't go! I had it diagnosed by aaa repair shop in los angeles. Have to pay 900 to get new throttle body unit.
The engine keep going into limp mode. The car stalls out while at lights an stop signs, power steering goes out on highway an other roads making it impossible to steer or steer out of others ways, limp mode causes car to not be able to keep up with traffic on highway and other roads. Engine jerks forward an shifts irractically an shifts an downshifts hard.
I was in heavy traffic and the car just stalled out on me while sitting at a light. Had to put my hazards on and try to restart car, restarted and then as soon as I put it into drive it stalled again. This happened 3-4 times until I could move to the next light and stop and go through the whole process all over again. Finally got on the highway and got home. Thought it was a fluke. Happened a second time while picking up children from daycare. Stalled out while at low RPM and would not restart. Had to have it towed. Had fuel filter replaced. Happened a third time at the store. Had to have it towed. Towed it to the dealer and the dealer spent over 6 hours to come to the conclusion that throttle body needed to be cleaned and PCM reprogrammed/updated. Without much confidence, they returned the car to me and said they could not replicate the problem. …
Related recalls (2)
Fuel system, gasoline › Storage › Tank assembly › Filler pipe and cap
Ford is recalling certain model year 2007 Ford five hundred and Mercury montego vehicles manufactured from September 5, 2006, through September 11, 2006. The fuel tanks May not have consistent welds between the fuel tank and fuel filler neck spud which can affect the strength of the joint.
Remedy: Dealers will replace the fuel tank free of charge. The safety recall began on August 16, 2011. Owners May contact Ford motor company customer relationship center at 1-866-436-7332.
Fuel system, gasoline › Storage › Tank assembly › Mounting
On certain passenger vehicles, the straps that secure the fuel tank to the vehicle body May break, causing the fuel tank and fuel tank heat shield to drop on the driveshaft (all wheel drive vehicles) or exhaust system (front wheel drive vehicles).
Remedy: Dealers will replace both fuel tank straps. The recall began on December 1, 2005. Owners May contact Ford at 1-800-392-3673.
Frequently asked questions
Which Ford Five Hundred years have fuel system problems?
By NHTSA complaints, the 2005 (44), 2006 (38) and 2007 (35) model years. Fuel System complaints make up 9% of all complaints for the 2005.
Is there a recall for Ford Five Hundred fuel system problems?
Yes — 2 recalls, including 11V-355 (filler pipe and cap, Jul 13, 2011); 05V-515 (mounting, Nov 9, 2005). Recall repairs are free at authorized dealers; check a specific car with the VIN recall check.
At what mileage do Ford Five Hundred fuel system problems start?
Across all years, half of the complaints with a recorded mileage happened before about 81,000 miles; 24% happened before 50,000 miles.
What part fails most often?
Owners most often name the delivery › hoses, lines/piping, and fittings (3 mentions), followed by the delivery (2).
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.