2022 Hybrid Fuel Tank Leak

[BAScott62]

Interesting, thanks for sharing! I thought they were different since the hybrid (I thought) had a smaller fuel capacity than the ecoboost. If they use the same design just with a different capacity, would make sense from an engineering perspective.

The presurization "stuff" is in the tank, so it takes up some of the volume.

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[kbuchle2]

I cheated on the math here (AI), but if gas was $3/gallon and you added .25 cents, you added 0.0833 gallon, or 10.66 ounces. Not a lot of extra there. I do like you, round up to next buck, have never had an issue. If my math is bad let me know. My wife of 52 years did ALL my algebra homework in high school. I barely passed the tests though! I paid her back, don't ask how! Merry Christmas!

That’s what I’ve always thought. Just makes things easier when I need to get change, either I don’t have to go and get it or don’t need a pocketful of coins.

Merry Christmas to you too!

 

[ripperAZ]

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.

Threaten or actually use the regional ombudsman. They’ll likely covered if you’re making a big stink about it most people don’t know there’s a regional guy that listens to all of dealer complaints and usually provide service to customers.

 

[kbuchle2]

Threaten or actually use the regional ombudsman. They’ll likely covered if you’re making a big stink about it most people don’t know there’s a regional guy that listens to all of dealer complaints and usually provide service to customers.

I ended up getting financial assistance from ford. Not 100% covered, but paying $100 was a lot better than $1100.

 

[kbuchle2]

Posting an update on this one, finally got my vehicle back on 01/12, I dropped it off to them on 12/11 so they had it for a whole month. I had to go through ford financial assistance, which I was told will never cover 100% of the cost. After getting a few different figures from them (they initially wanted me to pay $1100, then $300, and finally $100) I have a new tank installed.

The interesting thing? When I was “negotiating” with financial assistance and we were about to order parts, the service manager was working through the parts counter and he told me that the original part number for the fuel tank on my maverick was on stop-sale. That part number was NZ6Z-9002-C. Usually, manufacturers only put parts on stop-sale when they’ve identified an issue with them and they can’t sell them to the public. The new tank installed in my truck is NZ6Z-9002-D and it is noticeably different than NZ6Z-9002-C. Looking up NZ6Z-9002-D I can see it for sale through dealership websites, but not through parts.ford.com yet.

So do we have a recall incoming? I’ve seen a few additional posts on this forum for hybrids having this exact same gas tank issue, and I posted this same saga on the maverick subreddit and have had additional reports in the comments there. I’m sure many more have experienced this issue, they just aren’t active online. So hopefully ford issues a recall for this - leaking fuel/vapors is a major safety issue!

 

[kbuchle2]

Adding a (poor) pic of my new tank. I’ll add a better one when I have my car lift available to put my truck on.

 

[silvy]

Having same issue with my 2022 Hybrid. Taking it to dealer today.

 

[Glen Baker LLC]

The hybrid tank being pressurized, tends to exacerbate any small leak that may be there.

 

[Chops]

The hybrid tank being pressurized, tends to exacerbate any small leak that may be there.

The EVAP system works under vacuum sucking the vapors from the charcoal canister to the engine. A “normal” EVAP (EB) also has a vent valve that opens when engine is turned off to allow any minimal tank pressure to escape to atmosphere.

The Hybrid also has this vent valve but does not open to vent every time the Atkinson stops running. The positive pressure the gas tank builds up until the engine starts sucking vapors again is not great however.

If the vent valve gets stuck closed - you’ll have a tough time putting gas in you car. It will click off continually as you try to fill tank.

 

[Glen Baker LLC]

The EVAP system works under vacuum sucking the vapors from the charcoal canister to the engine. A “normal” EVAP (EB) also has a vent valve that opens when engine is turned off to allow any minimal tank pressure to escape to atmosphere.

The Hybrid also has this vent valve but does not open to vent every time the Atkinson stops running. The positive pressure the gas tank builds up until the engine starts sucking vapors again is not great however.

If the vent valve gets stuck closed - you’ll have a tough time putting gas in you car. It will click off continually as you try to fill tank.

Already knew that.

 

[Chops]

Already knew that.

Sorry - my inner Cliff Claven just has to butt in sometimes…obnoxious

 

[Glen Baker LLC]

Sorry - my inner Cliff Claven just has to butt in sometimes…obnoxious

Lot of folks especially if they've never driven a hybrid, don't realize that the gas tanks are pressurized. I got used to a pressurized fuel tank when I had my plug-in Chevy Volts.
I went close to 3 months on my Chevy Volt without ever adding fuel.
The engine would automatically start and run a few minutes every couple of weeks.
When I word press the button to open the fuel door, you could literally hear the hiss. I've not noticed that on my Maverick.
It's a matter of fact it's been a topic of discussion on the form, as to why does the hybrid have a locked fuel door that you have to press a button for it to open but the EcoBoost doesn't.

 

[Chops]

It's a matter of fact it's been a topic of discussion on the form, as to why does the hybrid have a locked fuel door that you have to press a button for it to open but the EcoBoost doesn’t

I’m still confused on why the Hybrid gas cap locks. Is the “hiss” from air rushing into tank or out of tank. Maybe unlocking it opens the vent valve to enable gas going in from the gas pump?

I thought EB vent valve opens when the truck is turned off - but I’m probably wrong. There might be a pressure sensor (using battery power) to open the vent valve when gas vapor pressure builds up from heat etc. I do hear my EB electronically & mechanically gurgle & chirp while sitting in garage hours / days after its last drive…

 

[Glen Baker LLC]

I’m still confused on why the Hybrid gas cap locks. Is the “hiss” from air rushing into tank or out of tank. Maybe unlocking it opens the vent valve to enable gas going in from the gas pump?

I thought EB vent valve opens when the truck is turned off - but I’m probably wrong. There might be a pressure sensor (using battery power) to open the vent valve when gas vapor pressure builds up from heat etc. I do hear my EB electronically & mechanically gurgle & chirp while sitting in garage hours / days after its last drive…

This may help.
I have yet to confirm whether or not the Maverick hybrid uses a bladder inside the tank or not. I have not physically seen a picture of one of the tanks cut open in order to positively verify. If somebody has a picture of it please post it.

 

[Chops]

This may help.
I have yet to confirm whether or not the Maverick hybrid uses a bladder inside the tank or not. I have not physically seen a picture of one of the tanks cut open in order to positively verify. If somebody has a picture of it please post it.

Thank you - that definitely helps me understand the Hybrid EVAP system better!

I was mistaking the “hiss” of the gas cap to the “hiss” of opening a jar of pickles (negative vacuum pressure).

Instead it is the “hiss” of positive pressure like opening the cap on the coolant system. And that would explain why the gas tank hose/clamp leaks are more common on the Hybrid.

You have just experienced the mind of an EB owner becoming enlightened Thank you for explaining & hope I did not waste too much forum time on this Hybrid basic!

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