2004 Ford Escape Fuel System Problems

While driving at 45 mph, you heard an unusual noise from the rear of your vehicle and smelled fuel inside the cabin. You discovered that the fuel tank straps had corroded and caused the fuel tank to detach from underneath your vehicle. You temporarily taped the straps and drove to a destination, then took the vehicle to a dealer, but it was not repaired. This issue involved the fuel tank's attachment system becoming compromised due to rust.

DRIVING 25 TO 30 MILES PER HOUR THROTTLE STICKS AT 3 RPMS . I HAD TO RIDE BRAKE TO PULL OVER SAFELY. I SHUT CAR OFF AND RESTARTED, IDLE WENT UP TO 3 RPMS AND SLOWLY WENT TO 1 RPM I DROVE CAR HOME WITH NO PROBLEM. I STARTED CAR TODAY WITH IDLE STICKING ON 2 TO 3 RPM BEFORE GOING BACK TO 1.

I FIRST NOTICED A SURGING AND SQUEAL TYPE NOISE WHILE COMING TO A STOP. SPOUSE HAD REPAIRED 3 TIMES YET IT CONTINUES. DURING THIS TIME I ALSO HEARD A CLANKING NOISE FROM REAR END AS IF HATCH (WINDOW/DOOR) WAS NOT SECURELY CLOSED BUT THEN ASSUMED IT MAY BE RELATED TO THE AFOREMENTIONED ISSUE. I MENTIONED NOISE INCREASED, LOUD, FRIGHTENING (STEERING DIFFICULTIES). HE CONTACTED FORD BY PHONE (X3) AND EMAILED HOWEVER THEIR REPLY WAS NO FATALITIES OR INCIDENTS HAD BEEN REPORTED THEREFORE WE HAVE 2 OPTIONS. 1) TAKE IT TO A FORD DEALER FOR REPAIR AT OUR EXPENSE, 2) TRADE IN FOR A NEW FORD VEHICLE. BOTH SCHOOL/CITY/GOVT EMPLOYED AND CANNOT AFFORD 2000.00 TO REPAIR. YESTERDAY MY HUSBAND REMOVED THE ENTIRE RIGHT SHOCK WHEN I RETURNED HOME FROM WORK AFTER A 12 HR DAY & TOLD HIM I FELT AS IF THE BACK END WAS GOING TO FALL OFF & CLANKING SOUND INTENSIFIED. AT 8PM HE WAS LAYING UNDER CAR ON GARAGE FLOOR AND FOUND THE SHOCK HANGING! HE WAS FORCED TO REMOVE AS I HAD TO WORK THE NEXT DAY AT 6AM. I AM DRIVING WITHOUT ONE SHOCK, NEW TIRES, RUSTED REAR FRAME AND SURGE CONTINUES. I WOULD APPRECIATE ANY SUGGESTIONS AS TO OTHER AVENUES FOR REPORTING. I HAVE 2 COWORKERS WITH SIMILAR ISSUES, BOTH ESCAPES. THE REMOVED SHOCK IS RUSTED, NEAR CRUMBLING OF SORT BUT SAVED ALONG WITH SEVERAL PHOTOS. THANK YOU IN ADVANCE FOR REVIEWING MY LENGTHY EMAIL AND LOOK FORWARD TO ANY INPUT AND RECOMMENDATIONS. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR UPDATED 1/21/15 *JS

WHILE DRIVING, THE THROTTLE STUCK. APPLIED THE BRAKES, BUT VEHICLE WAS DIFFICULT TO SLOW AND TACHOMETER INDICATED HIGH ENGINE SPEED. SHIFTING TO NEUTRAL, THE ENGINE RPMS PUT THE NEEDLE IN THE RED BEYOND THE GAUGE. AFTER SHUTTING OFF THE VEHICLE, AND OPENING THE HOOD THE PROBLEM DID NOT PERSIST, BUT RETURNED AFTER DRIVING AGAIN. *TR

TL* THE CONTACT OWNS A 2004 FORD ESCAPE. THE CONTACT STATED THAT THE VEHICLE FAILED TO START HOWEVER, ALL OF THE ELECTRICAL COMPONENTS WERE WORKING NORMALLY. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE CONTACT HAD THE FUEL PUMP REPLACED. FIVE YEARS PRIOR TO THE MOST RECENT FAILURE, THE SAME FAILURE OCCURRED AND THE VEHICLE WAS TAKEN TO THE DEALER WERE THE FUEL PUMP WAS REPLACED FOR THE FIRST TIME. THE VEHICLE WAS NOT RECENTLY REPAIRED FOR THE SIMILAR FAILURE. THE CURRENT MILEAGE WAS 34,000 AND THE FAILURE MILEAGE WAS 14,659.

WHILE BODY WORK WAS BEING CONDUCED AT A DEALER FOR A SCRAPED FENDER, DEALER EMPLOYEE STARTED VEHICLE AFTER PAINT OPERATIONS. THE INTAKE MANIFOLD INSTANTLY AND VIOLENTLY EXPLODED INTO SEVERAL PIECES. THE VEHICLE HAS APPROXIMATELY 80,000 MILE, WAS DRIVEN INTO THE DEALER FOR THE BODY WORK, AND HAS HAD NO SIMILAR PROBLEMS. THE DEALER REPORTS THAT THE VEHICLE STILL STARTS AND WILL HOLD AN ROUGH IDLE. THE TIMING BELT IS INTACT. THIS VEHICLE USES DIRECT FUEL INJECTION AND A DRY INTAKE SYSTEM. THE DEALER STATED THAT ALL PROCEDURES INCLUDING PAINTING PROCESS WERE PROPERLY FOLLOWED LEADING UP TO THE EXPLOSION. CAUSE IS UNKNOWN. THE VEHICLE IS STILL AT THE BODY SHOP FINISHING BODY WORK. NO RESOLUTION HAS BEEN REACHED CONCERNING THE MECHANICAL FAILURE. *TR

DT*: THE CONTACT STATED WHILE DRIVING 35 MPH THE VEHICLE STALLED. IT WAS PULLED OFF THE ROAD WITHOUT INCIDENT AND TOWED TO THE DEALER. THE FUEL PUMP AND FILTER WERE REPLACED. THREE DAYS LATER THE VEHICLE STALLED AGAIN WHILE BEING DRIVEN 35 MPH. THE VEHICLE RESTARTED AND WAS DRIVEN TO THE CONTACTS RESIDENCE. THE MANUFACTURER WAS NOT ALERTED.

IN NOVEMBER OF '03 I BOUGHT THE ESCAPE. NO PROBLEMS ALL WINTER. LAST WINTER OF '04-'05 I WAS HAVING PROBLEMS WHERE THE TRUCK WOULD NOT START UP RIGHT AWAY. THE DEALERSHIP TOLD ME IT WAS THE WINTER GAS AND THEY COULD NOT DUPLICATE THE PROBLEM. AFTER BRINGING IT BACK TO THE DEALER SEVERAL TIMES, THEY FINALLY GOT IT TO DUPLICATE. THEY REPLACED THE OXYGEN CELLINODE. UNFORTUNETLY THE PROBLEM JUST CAME BACK

ON FIVE (5) OCCASIONS OF FILLING UP MY 2004 FORD ESCAPE GAS TANK THERE HAS BEEN GAS SPILLAGE. GAS WILL COME FLYING BACK OUT OF THE TANK AFTER THE PUMP CUTS OFF. I TOOK THE ESCAPE BACK TO THE DEALERSHIP AND WAS TOLD NOTHING WAS CLOGGING OR IMPEDING THE FLOW OF GAS. I WAS TOLD NOT TO USE THE AUTOMATIC PUMP BECAUSE THE FLOW OF GAS MIGHT BE TOO FAST. I DO NOT USE THE AUTOMATIC PUMP ANYMORE AND THE PROBLEM STILL OCCURS. WHEN THE PUMP SITS IN THE OPENING FOR THE TANK THE PUMP IS AT AN UNEVEN LEVEL AND EVEN WHEN I PUMP SLOWLY SPILLAGE STILL OCCURS. (IT TAKES 5 MINUTES FOR ME TO GET 8 GALLONS OF GAS. I'VE TIMED IT.) THE PROBLEM HAS OCCURRED AT SEVERAL DIFFERENT GAS STATIONS. I HAVE ALSO TALKED WITH ANOTHER OWNER OF A FORD ESCAPE AND HE/SHE DOES NOT HAVE THIS PROBLEM. I HAVE TO KEEP A FULL BOTTLE OF WATER IN MY CAR TO RINSE OFF THE SPILLED GAS BEFORE IT DRIES ON THE SIDE OF MY CAR. THIS IS AN ANNOYING PROBLEM AND I'M TIRED OF DEALING WITH IT. *NM

WHEN FILLING THE GAS TANK, THE AUTOMATIC SHUT OFF WHEN THE TANK IS FULL DOES NOT FUNCTION. THIS LEADS TO EXCESS GAS SPILLING OUT. THIS HAS OCCURED AT NUMEROUS SELF-SERVE AND FULL SERVE GAS STATIONS INDICATING THAT IT IS NOT A PROBLEM WITH THE PUMP BUT A PROBLEM WITH THE DESIGN OF THE GAS TANK/INTAKE MECHANISM.*AK