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 2016 Ford Mustang owners, lightly cleaned up (personal details are redacted by NHTSA).
This specific car model is a 2016 Shelby GT350 tech package that I owned for at least 7 months. In this time period i had only put 7k mikes on it before it blew up. After doing tons of research there is a tons of class action law suits against Ford for these cars. The incident that occurred was while driving the vehicle caught fire on the passenger side. Driving at the speed limit of 40 MPH no warning lights, Check engine lights or anything it just blew up. Up to this point all maitence was done properly and after doing some research it had the same issue report by multiple other Shelby owners of this year. This vehicle is not safe for the roads and if not properly investigated, it can cause someone to lose their life. I incurred a bruised head, burns and loss of hair from this accident. I've contacted Ford in regards to this issue and yet to have anything done. …
The contact owns a 2016 Ford Mustang. The contact stated that after refueling the vehicle, there was an abnormally strong gasoline odor inside the vehicle. The vehicle was taken to an independent mechanic and the contact was informed that the fuel tank needed to be replaced because the cap on the fuel tank was fractured. The vehicle was repaired. The manufacturer was contacted and stated there was no recall for that failure. The contact was referred to the NHTSA Hotline to file a complaint. The failure mileage was 31,115. The consumer stated the vent nipple on the top of the gas tank failed.
I have had my 2016 mustang for 5 years already with 29k miles , my warrantee has expired. I recently notice I had check engine light for P0456 Evaporative Emission Leak. I took the car to get smoke test by my local shop mechanic and it came that there fuel vapor coming out of capless filler neck,since every ford model after 2013 don't have gas cap nomore I would have to replace the whole gas filler pipe which is around $500 for part and labor. In other cars you can just change gas cap for 20$ buh since in my case my car doesn't have gas cap i would have to replace the whole gas pipe filler and ford doesnt offer any gas cap for my car. I feel like if i do change my gas filler pipe , mabey couple years from now it's gona start giving same check engine problem. …
The new purge valve is faulty in my car. It has been replaced once in 2017, and another time in 2022 (possibly 2021), due to a total engine rebuild under powertrain warranty. This valve is a known common issue on online forums. For the model cars 2018 and 2019, this is an open recall. I strongly believe this should be investigated. In the past, this faulty valve caused my car to stall and die on a busy road. Both Ford customer service and the dealer have given me conflicting information whether or not this part is covered under emissions warranty, causing a headache. The dealer stated that if given a sequence of codes, the dealer has been instructed by Ford to replace the part for free. This indicates that Ford is aware of the common hazard that the faulty purge valve is causing. …
On or about June 24, 2026, the CHECK ENGINE light came on. Since I was near the local Ford Dealership, I stopped there. The car was evaluated the next day. I was told the the gas tank assembly and pipe had to be replaced. The repair was almost $4000. My car only as 63,117 miles on it. Before the problem was diagnosed, I was getting lousy gas mileage and assumed it was because the government was allowing more ethanol. In fact, the problem could have been disastrous... The car could have caught on fire . The car was in the repair shop until July 2, and I had to rent a car for $300. I am unable to download a photo I have of the gas tank which shows these numbers: E-11 34RI-020135 as well as AD46319. I have attached the bills from the CERTIFIED FORD repair shop. Please note that the 2015 Mustangs were recalled for gas tank replacements. I have a 2016.... …
I am looking for support concerning a possible defect with our 2016 Mustang V6. It appears to be a fuel tank defect. Causing our garage to completely smell like gas when the car is full of fuel. Similar to recall# 15v339-7601. Our car has a hairline fracture (according to our dealership service department). They attempted to repair the issue by replacing the EVAP line, instead found a crack in the EVAP nipple. According to our dealership the emissions warranty expired the week before we reported the issue in 2023. This is upsetting as I feel this is not a maintenance issue and more of a design flaw as Ford changed the design of the fuel tank after 2017. The dealership wants us to pay for this service but this is not our fault they fixed it incorrectly. I feel like this should be a recall or some sort of extended warranty from Ford for a design flaw.
On 12/06/2025 I filled the vehicle with gasoline. As I was driving home I noticd a strong odor of gasoline. When I arrived home I parked the car in my carport. A short time later I went outside and noticed that I could still smell gasoline and I looked under the car, which was approximately 3 feet from my house and saw a puddle under it. This could have caused a fire, so I immediately took the car to a repair shop. Approximately one hour later I received a call from the shop informing me that the tank was broken at the top and it would cost approximately $2,600 to replace the tank. The problem was confirmed by Gemba Automotive, Surprise, AZ. I am unaware of whether they have the part available for inspection. There were no warning messages or lights displayed on the driver information system.
Vehicle is 2016 garage kept, just under 18,000 miles. Check engine light is on. Code scanner indicates EGR leak. EGR valve replaced, check engine light reset. No code for about 3 weeks. Started getting gas filler warnings and check engine light back on again EGR issue. Getting ready for a road trip took vehicle to Ford to troubleshoot check engine light. Identified problem as a cracked fuel tank near where the filler connects. I researched what I can on-line and others have this same issue. Wondering if this is a defect?
At about 75k miles my mustang started misfiring at about 2,500 rpm's and higher. Turns out it was a blown head gasket. This engine model is prone to what happened to it. Ford should have a recall for these engine and a solution as they're ticking time bombs. I wish I could drive with the peace of mind of not worrying about it. I couldn't drive my car for months because of the warranty not even wanting to cover it. The warranty from the used car dealership. Got unlucky.
Noticed a fuel vapor odor for a couple of weeks. After filling the fuel tank the odor intensified. Drove the vehicle about 20 miles to my house. I could smell fuel when I exited the vehicle and noticed fuel leaking from the fuel tank. Took vehicle to the dealership, and when the tank was removed found the fitting for the evaporative system connection cracked. (See photos) There is no apparent impact that would have caused the crack.
Fuel System complaints in other Mustang years
Frequently asked questions
How common are fuel system problems on the 2016 Ford Mustang?
NHTSA has 21 complaints about the fuel & propulsion system of the 2016 Ford Mustang, 6% of the model year's 379 complaints. The component named most often is storage › auxillary tank (1 mentions).
Is there a recall for 2016 Ford Mustang fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2016 Ford Mustang, though it has 5 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 2016 Ford Mustang fuel system problems start?
Half of the complaints with a recorded mileage happened before about 31,000 miles, and 36% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 1 fire and 2 injuries and 2 deaths 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.