Ameer Randolph
Owners of 1999-2010 Ford Super Duty trucks should be aware of a problem that can affect the fuel tanks. The liner inside the factory fuel tanks on these models can delaminate and peel off in little flakes, contaminating the fuel lines and, in the worst-case scenario, clogging the fuel pump or injectors, which can be very expensive to fix. This article will discuss how to get the liner out of a Super Duty fuel tank and explore some possible replacement options.
Characteristics and Values
| Characteristics | Values |
|---|---|
| Models affected by the issue | 1999-2010 Ford F-250, F-350, F-450 Super Duty pickup, F-550 diesel cab and chassis, diesel E-Series van, or Class C motorhome |
| Problem | Liner inside the factory fuel tanks can delaminate and peel off in little flakes, clogging the fuel system and causing a loss of engine power |
| Solution | Have the Ford tank removed and boiled out, then apply a new liner by pouring in a liquid syrup and letting it cure (cost: $245-$400 plus labor) |
| Alternative solution | Replace the defective tank with an aftermarket version, such as the Titan Fuel Tanks replacement tank (cost: $896) |
| Skid plate option | Available for those who don't like the idea of a plastic fuel tank |
| Replacement tank option | Transfer Flow in Chico, California, offers a direct replacement for the defective Ford tanks ($855) with increased capacity and made of 12-gauge aluminized steel |
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$64.98
What You'll Learn
Fuel filter damage
Fuel filters screen debris and prevent it from entering the fuel system. A clogged fuel filter can starve your engine of fuel, causing the machine to crank longer and struggle to start. A dirty fuel filter could also be the reason for a misfiring engine. This is because a clogged filter causes an uneven distribution of fuel and can create low fuel pressure in your engine. A clogged fuel filter will cause the equipment to stutter and stall, especially when operating at low speeds.
If you drive a 1999-2010 Ford F-250, F-350, F-450 Super Duty pickup, F-550 diesel cab and chassis, diesel E-Series van, or Class C motorhome, you might encounter a problem with the fuel tank liner. The liner inside the factory fuel tanks on these models can delaminate and peel off in little flakes, which can clog the fuel filter and contaminate the fuel lines. In the worst-case scenario, this could lead to a clogged fuel pump or injectors, which can be very expensive to repair.
There are a few options to address this issue. One option is to have your Ford tank removed and boiled out by a competent shop. This process involves boiling the tank in a caustic solution of sodium hydroxide to remove the factory liner, followed by steam cleaning and flushing. A new liner is then applied by pouring a liquid syrup into the tank and letting it cure, which takes about three days. This procedure typically costs $245-$400 plus labor.
Another option is to replace the defective tank with an aftermarket version. Companies like Titan Fuel Tanks offer replacement tanks made of military-grade cross-linked polyethylene, which is claimed to be highly resistant to the corrosive effects of diesel fuel. These replacement tanks can also increase fuel capacity and are compatible with ASTM diesel fuels. Skid plates are also available as an alternative to plastic fuel tanks.
To prevent fuel filter damage and maintain the performance of your vehicle, it is important to regularly change your fuel filter according to the recommended intervals in your owner's manual. Additionally, regular preventive maintenance and professional services can help identify and address any issues early on, avoiding more expensive repairs in the future.
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Fuel line contamination
One way to prevent fuel line contamination is to ensure that the fuel filter is clean and replaced regularly. The fuel filter plays a crucial role in removing debris and contaminants from the fuel before it reaches the engine. However, over time, these particles can accumulate and clog the filter, leading to restricted fuel flow and reduced pressure. A clogged filter can also cause the fuel pump to work harder, resulting in inefficient fuel delivery.
To fix a contaminated fuel line, it is essential to identify the source of the contamination and address it promptly. This may involve repairing or replacing damaged fuel lines, cleaning or replacing the fuel filter, or fixing leaks in the fuel system. In some cases, a fuel system cleaner can be added to the fuel tank to help remove contaminants and build-up from the fuel tank, fuel lines, and injectors.
For certain vehicles, such as the 1999-2010 Ford Super Duty models, there is a known issue with the factory fuel tanks. The liner inside these tanks can delaminate and peel off in little flakes, contaminating the fuel lines and potentially leading to clogged fuel pumps or injectors. In such cases, one possible solution is to have the Ford tank removed and boiled out by a competent shop. This process involves removing the factory liner, steam cleaning and flushing the tank, and then applying a new liner. Another option is to replace the defective tank with an aftermarket version, such as the one offered by Titan Fuel Tanks, which is made of military-grade cross-linked polyethylene.
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Clogged fuel pump
The fuel pump plays a crucial role in making your car move. It sends gas from the fuel tank to the engine. Typically, you don't have to replace your fuel pump until your vehicle has at least 100,000 miles on it, and fuel pumps can last for over 200,000 miles.
If you drive a 1999-2010 Ford Super Duty pickup, F-550 diesel cab and chassis, diesel E-Series van, or Class C motorhome, you may encounter a problem with the fuel tank liner. The liner inside the factory fuel tanks on these models can delaminate and peel off in little flakes, contaminating the fuel lines and leading to a clogged fuel pump.
A clogged fuel pump can cause the vehicle to struggle to start or not start at all, as fuel isn't getting to the engine. The engine may sputter or stall while driving, as it isn't getting the required fuel and air mixture to initiate combustion. You may also notice your engine surging, repeatedly picking up and dropping speed without any input from the driver. Additionally, a clogged fuel pump can lead to lower gas mileage due to damaged or worn components allowing excess fuel into the engine.
There are a few options to address a clogged fuel pump caused by a defective fuel tank liner. One option is to have the tank removed and boiled out by a competent shop. This process involves boiling the tank in a caustic solution of sodium hydroxide to remove the old liner, followed by steam cleaning and flushing. A new liner is then applied using a liquid syrup, which is cured for three days. This procedure typically costs between $245 and $400, plus labor.
Another option is to replace the defective tank with an aftermarket version, such as the Titan Fuel Tanks replacement tank made of military-grade cross-linked polyethylene, which is claimed to be highly resistant to the corrosive effects of diesel fuel. This option costs around $896.
It is important to address a clogged fuel pump issue promptly to avoid further complications and ensure the safe and efficient operation of your vehicle.
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Replacement tank options
There are several options for replacing the fuel tank in a Super Duty vehicle. The first option is to simply replace the defective tank with another Ford tank. This option is likely to be expensive, with the tank itself costing between $1211 and $2420, and labor costs for R&R (removal and reinstallation) of the tank ranging from $200 to $450.
Another option is to replace the defective tank with an aftermarket version. Titan Fuel Tanks offer a replacement tank constructed of military-grade cross-linked polyethylene, which is said to be "virtually impervious to the corrosive effects of diesel and most biodiesel fuel blends". This option costs $896, and the original straps and sending units can be reused. Transfer Flow also offers a direct replacement for defective Ford tanks, which increases the capacity by 7 gallons and is made of 12-gauge aluminized steel. This option costs $855, and new hold-up straps are supplied.
If you are looking for a larger replacement tank, Titan offers 50-gallon and 65-gallon replacement fuel tanks for the 2011-2015 Ford F250/350 Super Duty 6.7L, as well as a 60-gallon in-bed fuel tank option. These replacement tanks can double the amount of fuel you can carry and can be combined with an in-bed auxiliary or spare tire replacement for even more capacity.
For those who prefer a gas replacement tank, options are more limited. Transfer Flow, Titan, and S&B offer a range of diesel fuel vehicle-specific replacement tanks, but there are fewer options for gasoline tanks. It is worth noting that some companies, like Titan, specify that their replacement tanks are not rated for gasoline, so it is important to check the specifications before purchasing.
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Skidplates
Skid plates are available for those who do not like the idea of a plastic fuel tank. The first step in installing a skid plate is to remove the plastic heat shield attached to the driver-side frame rail. There are four bolts in total, two forward and two backward, that need to be removed. The front bracket should then be loosely mounted using an HB1 bolt, a locknut, a flat washer, and a lock washer purchased from a hardware store. The skid plate can then be mounted, which can be challenging for one person to do alone. Once the bolt holes are lined up, the front bracket can be tightened. Finally, re-attach the four bolts and two nuts that were removed earlier.
Skid plates are available for purchase from several websites, including FordPartsGiant.com and tascaparts.com. The cost of skid plates varies depending on the model and retailer, ranging from $61 to $290. Some websites offer free shipping, expedited delivery, and hassle-free return policies. It is also possible to find used skid plates on local junk yards or forums.
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Frequently asked questions
You may experience a weird vibration, like a tyre is out of balance. This will get worse and could feel like the engine is running on six cylinders.
The first thing to check is the fuel filter, either in the tank or the main filter. The fuel lines may also be contaminated, and you could be looking at a clogged fuel pump or injectors.
The problem is that the liner inside the factory fuel tanks on these models can delaminate and peel off in little flakes, causing issues with the fuel system.
The least expensive solution is to have your Ford tank removed and boiled out by a competent shop. This will cost $245-$400 plus labour. You can also replace the defective tank with an aftermarket version, such as the Titan Fuel Tanks replacement tank constructed of military-grade cross-linked polyethylene ($896).
