Katerina Swanson
Ford truck owners have been facing a common issue of fuel tank delamination, especially in models manufactured between 1999 and 2010. This problem occurs when the laminate coating inside the fuel tank peels off and gets sucked into the fuel system, leading to clogged fuel filters, pumps, and injectors. While Ford has denied responsibility and refused to issue a recall, owners have had to bear the costs of repairs and replacements, which can be expensive. To address this issue, some owners have opted for cleaning and resurfacing the tank, while others have chosen to replace the steel tank with a polyethylene version, which is impervious to the corrosive properties of certain diesel fuels.
| Characteristics | Values |
|---|---|
| Affected Models | Ford F-250 through F-550 vehicles ('99 to '10), F-650 and F-750 trucks ('99 to '10) |
| Cause | Liner inside the factory fuel tanks can delaminate and peel off |
| Symptoms | Bucking and stalling at idle, loss of power, clogged fuel filters, debris in the fuel lines, clogged fuel pump, damaged injectors |
| Solution | Replace the fuel tank with a polyethylene version, install an inline fuel filter, clean and resurface the tank |
| Cost | Replacement tank: $854.52-$895.90 plus shipping and handling; Repairs: $1800+ |
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What You'll Learn
Identify the cause of delamination
The cause of delamination in Ford fuel tanks has been a topic of debate. The problem primarily affects Ford diesel trucks and E-Series vans from the model years 1999 to 2010, with some reports extending to 2008 or 2011 models.
Ford attributes the issue to two specific variants of diesel fuel: Biodiesel and Ultra Low Sulfur Diesel. The corrosive properties of these fuels are believed to strip the laminate coating from the inside of the tank, causing internal clogging and potential failure of the entire fuel system.
Other experts argue that the problem is not limited to diesel fuels and that additives in the fuel, such as methanol and sulfuric acid, are to blame. These additives are more prevalent in modern diesel fuels and can have solvent-like effects, corroding various components of the fuel system, including the tank lining.
Some owners of Ford vehicles have reported issues such as bucking, stalling, and unusual vibrations at idle, which are symptoms of fuel tank delamination. While Ford has not issued a recall for these vehicles, they did release a "secret" service bulletin to dealers and service locations regarding the potential issue.
The delamination issue appears to occur between 20,000 and 120,000 miles, and it is not limited to diesel engines, as gasoline vans using Ford OEM painted steel tanks have also experienced similar problems.
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Drain the fuel tank
Draining the fuel tank is a crucial step in cleaning a delaminated Ford fuel tank. Here is a comprehensive guide on how to effectively drain the fuel tank:
Firstly, determine how much fuel needs to be drained from the tank. If you are dealing with a significant amount of fuel, such as 38 gallons, you may need to use a combination of methods for efficiency and safety. Start by using a hose and an air compressor to pump out the fuel. Shove the hose down the fill tube, stuff a rag around it, and insert the end of a blow gun from the air compressor. This will help you pump out the fuel into buckets or containers.
Next, to ensure a thorough draining process, you may need to drop the tank. This involves removing the fuel tank from the vehicle. Use a jack with a 2x6 to spread the pressure across the tank. Apply some pressure with the jack, remove the bands, and have an assistant help stabilize the tank as you lower it.
Now, locate the metal fuel drain tube. Slip a tube that matches the size of the drain tube, such as a 3/8 or 5/16 tube, over it and route it to a fuel can or container. You will need multiple containers, depending on the fuel volume.
Additionally, you can utilize the fuel pump to aid in draining the tank. Disconnect the fuel line that goes from the filter to the engine. Attach a 5/16" fuel hose to the filter outlet, ensuring it is long enough to reach your fuel container. Remove the fuel pump relay and use a jumper wire to connect the terminals. Turn on the key to activate the pumps and drain the fuel.
For safety, it is important to be cautious of fuel vapors and fumes. When dealing with gasoline fumes, keep any potential sources of sparks, such as electric motors, at a safe distance.
Finally, if you are unable to drain the tank completely, consider using fuel stabilizers to preserve the remaining fuel. You can also run the vehicle to use up the remaining fuel before refilling with fresh fuel and changing the fuel filter.
By following these steps, you can effectively drain the fuel tank of your Ford vehicle, which is an essential step in addressing delamination issues and maintaining your fuel system.
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Clean the fuel tank
If you own a Ford diesel truck or E-Series van from the model years 1999 to 2010, your fuel tank may be susceptible to delamination. This issue arises when the laminate coating on the inside of the tank breaks down and is sucked through the fuel system, leading to clogged fuel filters, pumps, and injectors. While Ford has denied responsibility for this issue, there are several steps you can take to clean and maintain your fuel tank to mitigate the problem.
Begin by draining the fuel from the tank. Next, you'll need to clean the HFCM (Hot Film Air Mass Meter), which measures the air entering the engine. It is important to clean this component as it can become clogged with delaminated particles, leading to inaccurate readings and potential engine performance issues. After cleaning the HFCM, replace the fuel filters, as they are likely to be contaminated with delaminated particles.
Now, you can focus on the fuel tank itself. Remove the tank and scrape away any visible delamination from the inside. Clean the exterior of the tank and, if necessary, use a grinder with wire brush cups and fine flap wheels to remove any remaining corrosion. Treat the tank with phosphoric acid to address any invisible microscopic corrosion. Allow the acid to sit for 24 hours, then neutralize and rinse the tank thoroughly to remove any acid residue.
Finally, reassemble the fuel tank and consider applying a new coating to prevent future delamination. One option is to use a polyethylene tank, which is impervious to the corrosive properties of diesel fuels and their additives. This will help prevent future delamination and protect your fuel system from damage.
By following these steps, you can effectively clean and maintain your Ford fuel tank, mitigating the issues caused by delamination and ensuring the optimal performance of your vehicle.
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Replace the fuel tank
If you own a Ford diesel truck or E-Series van from the model years 1999-2010, your fuel tank may be susceptible to delamination. This issue has also been observed in some 1996 and 1997 Ford F-250 and F-350 pickups, as well as 1999 to 2010 F-650 and F-750 trucks.
The root cause of delamination is debated, but it is believed to be related to the corrosive properties of certain diesel fuels, such as biodiesel and ultra-low sulfur diesel, or the additives in these fuels. As a result, the laminate coating on the inside of the tank breaks down and is sucked through the fuel system, leading to clogged fuel filters, pumps, and injectors.
While some owners have attempted to clean and recoat their fuel tanks, a long-term solution is to replace the fuel tank with a polyethylene version, which is impervious to the corrosive properties of these diesel fuels. Companies like Raybuck offer replacement tanks that fit OEM specifications and are easy to install.
- Purchase a replacement fuel tank: You can source a replacement tank from companies like Raybuck, which offers polyethylene tanks that fit OEM specifications. Another option is to purchase a replacement tank from companies like Titan Fuel Tanks, which produces military-grade, cross-linked polyethylene tanks that are resistant to corrosive diesel fuels and additives.
- Remove the old fuel tank: Drain the fuel from the tank and disconnect all fuel lines, hoses, and electrical connections. You may need to remove any mounting brackets or straps holding the tank in place. Be sure to follow safety procedures and have a qualified technician perform this work if you are unsure.
- Install the new fuel tank: Position the new fuel tank in place and secure it using the appropriate mounting hardware. Reconnect all fuel lines, hoses, and electrical connections, ensuring they are properly secured and sealed.
- Refill and test: Refill the new fuel tank with fresh fuel and check for any leaks or issues. Start the engine and ensure that the fuel system is functioning properly.
By replacing your Ford fuel tank with a polyethylene version, you can prevent the issues caused by delamination and ensure the long-term reliability of your vehicle's fuel system. While Ford has been reluctant to acknowledge and address this issue, taking matters into your own hands can save you from costly repairs and headaches down the road.
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Seek reimbursement from Ford
If you own a Ford diesel truck or E-Series van from the model years 1999 to 2010, you may encounter a delamination issue with your fuel tank. Ford has been made aware of this problem and has even been sued in a New Jersey federal court for selling F-Series pickup trucks and E-Series vans with allegedly defective fuel tank linings. Despite this, Ford has refused to admit that this constitutes a defect and has not issued a recall for these vehicles.
Ford's warranties do not cover fuel lines and fuel tanks, and they will often claim that the use of biofuel caused the delamination. However, this problem is not limited to biofuel and has been reported even when no additives have been used.
To seek reimbursement from Ford for the cost of repairing or replacing your delaminated fuel tank, you can try the following steps:
- Gather evidence: Collect any documentation or evidence that supports your claim, including repair records, receipts, and photos of the delamination.
- Contact Ford: Reach out to Ford customer service and explain the issue you have been experiencing with your fuel tank. Provide them with the evidence you have gathered and request reimbursement for the repairs or replacement.
- Reference previous cases: Bring attention to the fact that Ford has reimbursed customers in the past for similar issues, such as the 1993 F250 incident where fuel flooded the engine, resulting in Ford reimbursing affected customers.
- Seek legal advice: If Ford refuses to reimburse you, consider consulting a lawyer or legal expert who can guide you through your options, which may include joining or initiating a class-action lawsuit against Ford.
- File a complaint: You can file a complaint with the National Transportation and Safety Commission, as suggested by the Law Office of Howard Gutman. This can be done by finding the relevant website and filling out a form explaining the issue.
- Explore alternative solutions: While seeking reimbursement from Ford, also explore alternative solutions to address the delamination issue. This could include replacing your fuel tank with a polyethylene version, which is impervious to the corrosive properties of biodiesel and ultra-low sulfur diesel. Companies like Raybuck and Titan Fuel Tanks offer replacement tanks made from military-grade, cross-linked polyethylene.
Remember, you are not alone in this issue, and by taking collective action, Ford customers can increase the pressure on the company to acknowledge and address this widespread problem.
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Frequently asked questions
Delamination is when the liner inside the factory fuel tanks peels off in little flakes, clogging the fuel filter and fuel lines, and eventually leading to a clogged fuel pump or damaged injectors.
The cause of delamination is debated. Ford believes it is caused by two variants of diesel fuel: biodiesel and ultra-low-sulfur diesel. Other experts blame the problem on the additives in diesel fuel.
Some signs of fuel tank delamination include a loss of power, bucking, and stalling at idle.
To prevent fuel tank delamination, you can replace your fuel tank with a polyethylene version, which is impervious to the corrosive properties of diesel fuel and its additives.
To clean a delaminated fuel tank, you can remove the debris clogging the fuel filters, clean the exterior filter, and reassemble the tank. You may also need to replace the fuel pump and fuel injectors.
