2022 Hybrid Fuel Tank Leak

[kbuchle2]

Hi Maverick Truck Club,

I’ve been dealing with a gas tank leak since the fall of 2024 when I started noticing a gasoline smell coming out of my garage when I opened the overhead door. Thought that it may have been a gas can or something causing the smell, but noticed a leak coming from the fill pipe inlet when I had it up on the lift at home at the end of the year. Took the vehicle under warranty to the ford dealer, and was told that the hose clamp was loose connecting the fill pipe into the fuel tank itself that they confirmed was fixed wire a smoke test. Truck had 18000 miles and was just a couple months shy of 3 years old.

Was sent on my way with the vehicle, and noticed a smell of gasoline and fuel not even two months later (at this point out of bumper to bumper warranty.) Took it back to the dealer and was told that they were unable to replicate any leaking detectable by their smoke test, and that I was good to go. I didn’t see any evidence of a leak nor did I smell any gas from April to November (warmer months in Michigan.)

Once the weather got cold again, took the vehicle back after noticing a much larger leak and smelling fuel during an oil change on the lift again, and am now being told by ford that the fuel tank does in fact need to be replaced as the tank is leaking from the fill pipe inlet. I am no longer under warranty and was quoted $1100 for this repair. Dealership is telling me that the leak was hard to detect as it weeps fuel from that area of the tank in the cold weather (which explains why I was seeing this last winter before the warranty was up and why I wasnt noticing it over the summer when it was warmer.)

I tried to include a pic a took from the rear of the truck, looking at the fill pipe inlet between the torsion beam.

Anybody else running into this problem? I found an old thread from 2022/2023 from someone with a hybrid like me that seemed to have the exact same issue, but it is seeming to not be very widespread.

Also, anyone that has experience wirh ford customer support - is there anyway to get this covered? I feel like this was misdiagnosis on my dealers part when it was under bumper to bumper and since it’s a fuel tank leak, I can’t just let this go without resolving it. It sounds like I may qualify for some “financial assistance” per the dealership but they said it will not be covered 100%, which I feel it should - between misdiagnosis and me bringing it in now for the 3rd time for this issue.

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[Chops]

This is why dealers get a bad reputation - bad apples here & there. They should have acknowledged the leak under 3/36 when you brought it in but instead pushed you off. Hopefully they documented your concern while under 3/36 - and would honor based on that timing.

But they probably have no record of your suspected tank leak. If they did document your concern - you have a strong case for Ford to cover it under warranty.

I had a new GMC Canyon that had leak marks on the rear differential. There was also a TSB for this issue. GMC told me it was normal grease weeping from assy - but they noted it & told me it would be covered in the future based on the date I brought it to their attention. It never got worse - it was normal grease remnants from assy…

 

[kbuchle2]

This is why dealers get a bad reputation - bad apples here & there. They should have acknowledged the leak under 3/36 when you brought it in but instead pushed you off. Hopefully they documented your concern while under 3/36 - and would honor based on that timing.

But they probably have no record of your suspected tank leak. If they did document your concern - you have a strong case for Ford to cover it under warranty.

I had a new GMC Canyon that had leak marks on the rear differential. There was also a TSB for this issue. GMC told me it was normal grease weeping from assy - but they noted it & told me it would be covered in the future based on the date I brought it to their attention. It never got worse - it was normal grease remnants from assy…

Thanks for the reply - this is helpful! I did get an acknowledgment when I first brought it in, they could see the staining running down the side but a bit worse than what I showed in the pic above. I do have a documented service record of my concern and that they verified it, but that the smoke test just showed a small leak that was fixed when they tightened the worm clamp.

Agree with you that i have a strong case - I’m just not sure how to go about getting it covered. I called ford directly and at the time my case advisor told me that I would qualify for “financial assistance” - bur gave me no info on what that would be, since I hadn’t dropped it at the dealer again for re-check. Dealer called me today and told me financial assistance again, and that they were in contact with ford. Then ford called me at the end of the day to tell me what they had heard from the techs and that the cost was $1100 and if i was ok with that - to which of course I said no. Then she offered financial assistance again, but that she will have to talk to the dealer after the holidays - didnt tell me how much but she was certain that it would not be 100%, as I feel it should.

With all of that said, I don’t really know what other tree to bark up. Seems like my ford contact was clueless/not listening to me and the dealer hasn’t really said anything to me about $ yet, other than working with ford.

The canyon story does help here since it is the same thing that im going through, so thanks for sharing that. Sounds like a good dealership that was trying to help out a customer and give them some assurance for the future. Glad you didnt have to take them up on it.

 

[Master Blaster]

Was there not a recall on 22 models where the factory drilled through the bed floor and into the tank, causing a leak?

 

[kbuchle2]

Was there not a recall on 22 models where the factory drilled through the bed floor and into the tank, causing a leak?

You’re correct, mine was built just after that window ended. I think that was for mavericks built in late 2021, mine is a feb 2022 build.

 

[rywt74]

Hi Maverick Truck Club,

I’ve been dealing with a gas tank leak since the fall of 2024 when I started noticing a gasoline smell coming out of my garage when I opened the overhead door. Thought that it may have been a gas can or something causing the smell, but noticed a leak coming from the fill pipe inlet when I had it up on the lift at home at the end of the year. Took the vehicle under warranty to the ford dealer, and was told that the hose clamp was loose connecting the fill pipe into the fuel tank itself that they confirmed was fixed wire a smoke test. Truck had 18000 miles and was just a couple months shy of 3 years old.

Was sent on my way with the vehicle, and noticed a smell of gasoline and fuel not even two months later (at this point out of bumper to bumper warranty.) Took it back to the dealer and was told that they were unable to replicate any leaking detectable by their smoke test, and that I was good to go. I didn’t see any evidence of a leak nor did I smell any gas from April to November (warmer months in Michigan.)

Once the weather got cold again, took the vehicle back after noticing a much larger leak and smelling fuel during an oil change on the lift again, and am now being told by ford that the fuel tank does in fact need to be replaced as the tank is leaking from the fill pipe inlet. I am no longer under warranty and was quoted $1100 for this repair. Dealership is telling me that the leak was hard to detect as it weeps fuel from that area of the tank in the cold weather (which explains why I was seeing this last winter before the warranty was up and why I wasnt noticing it over the summer when it was warmer.)

I tried to include a pic a took from the rear of the truck, looking at the fill pipe inlet between the torsion beam.

Anybody else running into this problem? I found an old thread from 2022/2023 from someone with a hybrid like me that seemed to have the exact same issue, but it is seeming to not be very widespread.

Also, anyone that has experience wirh ford customer support - is there anyway to get this covered? I feel like this was misdiagnosis on my dealers part when it was under bumper to bumper and since it’s a fuel tank leak, I can’t just let this go without resolving it. It sounds like I may qualify for some “financial assistance” per the dealership but they said it will not be covered 100%, which I feel it should - between misdiagnosis and me bringing it in now for the 3rd time for this issue.

I discovered the exact same issue on my 2022 XLT this week. My son has been driving the vehicle and always parks outside here in Arizona. He came home for the holidays and parked in our garage and we noticed a strong smell of gasoline. I have older vehicles in a motorcycle in the garage so figured it was one of those. After an extensive search, I realized it was fuel leak leaking out of the inlet of the tank on the Maverick. I checked the hose clamp, which was tight. From what I can tell it looks like it’s leaking from the white or rubber gasket between the flange and the tank. I am curious if that flange is something that can be replaced or is attached to the tank? I have included some pictures that were taken after I cleaned the area up. There was black gunk around the white flange and a stream of fuel leaking down the bottom of the tank We were going to take it into the dealer but if they’re gonna charge me 1100 bucks for a new tank and I might as well put it on myself. I am not a mechanic, but I can’t understand why you would put a fuel inlet in the middle of a tank. Every tank I’ve seen has the inlet on the top. This of course, makes it difficult to attach the hose, but makes much more sense to help prevent leaks.

 

[Glen Baker LLC]

I wonder, if the hybrids pressurized fuel tank makes the condition more noticeable.

 

[kbuchle2]

I discovered the exact same issue on my 2022 XLT this week. My son has been driving the vehicle and always parks outside here in Arizona. He came home for the holidays and parked in our garage and we noticed a strong smell of gasoline. I have older vehicles in a motorcycle in the garage so figured it was one of those. After an extensive search, I realized it was fuel leak leaking out of the inlet of the tank on the Maverick. I checked the hose clamp, which was tight. From what I can tell it looks like it’s leaking from the white or rubber gasket between the flange and the tank. I am curious if that flange is something that can be replaced or is attached to the tank? I have included some pictures that were taken after I cleaned the area up. There was black gunk around the white flange and a stream of fuel leaking down the bottom of the tank We were going to take it into the dealer but if they’re gonna charge me 1100 bucks for a new tank and I might as well put it on myself. I am not a mechanic, but I can’t understand why you would put a fuel inlet in the middle of a tank. Every tank I’ve seen has the inlet on the top. This of course, makes it difficult to attach the hose, but makes much more sense to help prevent leaks.

You are spot on, I have the same leak coming from the exact same location. I noticed it last fall running down from that area and down the side of the tank, you could easily smell fuel in my garage. I think other people that park outside like you mentioned may not notice this so easily.

I tried looking at the parts catalog online to see how the tank is constructed, it looks to me that the white inlet piece is a part of the tank itself, which I think lines up with what the dealer is telling me. To replace the tank, (in MI at least) the rank itself is $800 and the labor is $300.

My dad and I said the same thing when we first saw that design with the fill coming into the side of the tank. Living in MI, both of us have worked for the big 3 and every car you see (going back decades) uses the fill on the top. Maybe the pressurized tank allows them to fill in from the side, but puts a lot of pressure on any joints like this in the tank. They had a very hard time tracking the leak down, telling me it was a loose hose clamp and now saying that it’s the entire tank assembly to be replaced.

 

[kbuchle2]

I wonder, if the hybrids pressurized fuel tank makes the condition more noticeable.

I wouldn’t doubt it. I’m not 100% sure but I think that the ecoboost also has the fill come in from the top, not the side like the hybrid. I could be wrong on that but I believe that’s what I saw on the ford parts catalog. Dealer also tells me that the condition worsens in cold weather, which explains why I never saw it in the summer and it gets very bad in the winter (I live in MI.)

 

[Glen Baker LLC]

I don't know if this thread helps or not.
https://www.mavericktruckclub.com/f...l-tank-recall-maverick-hybrid-underbody.7718/

 

[rywt74]

I wonder, if the hybrids pressurized fuel tank makes the condition more noticeable.

I am sure you are right, especially with reports of temperature affecting the amount of fuel leaking.

 

[icegradner]

I am sure you are right, especially with reports of temperature affecting the amount of fuel leaking.

If this becomes a wide spread issue, I would hope that Ford does something about it. When I get some dry weather I'll have to check mine out, at least I have the extended warranty for stuff like this.

 

[kbuchle2]

I don't know if this thread helps or not.
https://www.mavericktruckclub.com/f...l-tank-recall-maverick-hybrid-underbody.7718/

Awesome video that I had not seen before. Many thanks for sharing!

 

[kbuchle2]

If this becomes a wide spread issue, I would hope that Ford does something about it. When I get some dry weather I'll have to check mine out, at least I have the extended warranty for stuff like this.

If you do run into any fuel leaking, please report it on NHTSA site. I reported mine after the dealer called me yesterday to update me on this. The more people report, the better likelihood that we have to get a formal recall.

 

[Glen Baker LLC]

Awesome video that I had not seen before. Many thanks for sharing!

Your welcome.
Merry Christmas & Safe New Year

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