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2022 Hybrid Fuel Tank Leak

Chops

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It was worse for me when it was cold outside, like it is right now. I would get the leak running down from that seal all the way down the side of the tank. Would never notice it when it was warm outside.
I just learned today that the gas tank is under a slight positive pressure - anywhere from 0psi to 5psi max. Normally 2-3 psi. Much lower than the 15-20 psi of the coolant system…

0 psi while running to a max of 5 psi
after sitting a while on a very hot day.

Cracks in rubber open up more in the cold. Therefore I’m guessing your leak is caused more by the coldness of the crack in hose than the very slight psi in the cold tank.

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Sherlock Claven
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kbuchle2

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I just learned today that the gas tank is under a slight positive pressure - anywhere from 0psi to 5psi max. Normally 2-3 psi. Much lower than the 15-20 psi of the coolant system…

0 psi while running to a max of 5 psi
after sitting a while on a very hot day.

Cracks in rubber open up more in the cold. Therefore I’m guessing your leak is caused more by the coldness of the crack in hose than the very slight psi in the cold tank.

Signed,
Sherlock Claven
Agree with you. Pressure wise, would think in the summer things would be worse. But in the winter, the rubber contracts, and that causes it to leak/weep worse than it normally would. Initially the dealer told me that the house clamp on the fill pipe connecting to the nipple on the tank was loose, causing the leak from that area. I was skeptical and after they tightened it, it didn’t improve things. Then after bringing it back 2 more times (and getting ford technical support involved) they told me that the leak was caused by a break in the tank itself, and would be replaced. I came and got it and it’s a different part number and the tank has many changes. Not least of which is that blue nipple/seal area that so many have pointed out leaking issues from.
 

Chops

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Agree with you. Pressure wise, would think in the summer things would be worse. But in the winter, the rubber contracts, and that causes it to leak/weep worse than it normally would. Initially the dealer told me that the house clamp on the fill pipe connecting to the nipple on the tank was loose, causing the leak from that area. I was skeptical and after they tightened it, it didn’t improve things. Then after bringing it back 2 more times (and getting ford technical support involved) they told me that the leak was caused by a break in the tank itself, and would be replaced. I came and got it and it’s a different part number and the tank has many changes. Not least of which is that blue nipple/seal area that so many have pointed out leaking issues from.
I wonder when/if the “blue seal” redesign tank entered production. And if it is Hybrid only as opposed to both EB & Hybrid sharing as usual. Going to have to grab a flashlight and see if I can spot the seal on my 25 EB;)
 

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Agree, unless there was some glaring defect with the tank proper, the bean counters wouldn't pay for new molds but rather redesign the seal(s), which it appears they have done. Depending on how that nipple/seal is installed by the factory, there *might* be a future field modification kit by Ford or aftermarket to replace, if it reached critical failure rates. Until then, for out of warranty fails, a big gob of JB Weld Red ;)
I had a Maverick Lariat that got shipped to a lot outside of Chicago and just sat there. Didn't get delivered to the dealer because (I found out later) of a "potential" of a gas tank leak. I got a letter saying the machine that welded the plastic gas tank suffered a power loss to some of the welding clamps and a few of the tanks might leak. I immediately ordered another Mav and it came in before they fixed the potentially leaking one so I never found out what happened to it. It took so long because they ran out of good tanks.
 

Chops

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The fuel tank for 2025 is rev “-D” and the 22-24 is “-C”.

D more expensive, but picture looks the same as C (on the outside).

Ford Maverick 2022 Hybrid Fuel Tank Leak IMG_0465
Ford Maverick 2022 Hybrid Fuel Tank Leak IMG_0464
 

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Chops

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Are these for EcoBoost or hybrid??
It is my understanding that both Hybrid & EB have always shared the same gas tank. Hopefully the EB benefits from a more robust tank than vice versa.

Edit - nope, my 25 EB uses a different tank part# rev -A.
Looks the same on outside but probably lacks the internal baffles etc of the Hybrid

Ford Maverick 2022 Hybrid Fuel Tank Leak IMG_0468
 
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Glen Baker LLC

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It is my understanding that both Hybrid & EB have always shared the same gas tank. Hopefully the EB benefits from a more robust tank than vice versa.
I understand the same thing.
Basically the same tank. I always figured it was the EcoBoost tank that was adapted for the hybrid use.
 

Chops

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I understand the same thing.
Basically the same tank. I always figured it was the EcoBoost tank that was adapted for the hybrid use.
Toyota uses different gas tanks on models that run ICE and Hybrid.

Hybrid tanks are shaped differently and typically smaller capacity…
- maybe to reduce weight & improve mpg?
- maybe to fit better with the battery package etc?
- maybe to handle the slightly higher pressure of the hybrid’s stricter EVAP system?
 
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Chops

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I understand the same thing.
Basically the same tank. I always figured it was the EcoBoost tank that was adapted for the hybrid use.
Update - AI states the Hybrid uses a different tank than the EB.

The rev -D may be hybrid & not EB?
AI days there is a simpler rev -A for EB.

My 25 ecoboost uses the rev -A
Ford Maverick 2022 Hybrid Fuel Tank Leak IMG_0468
 
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The 2025 Ford Maverick Hybrid features a smaller 13.8 gallon fuel tank designed for high city efficiency (42 MPG), while the 2.0L EcoBoost gas model has a larger 16.5 gallon fuel tank.
So says A. I.
 

Glen Baker LLC

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The 2025 Ford Maverick Hybrid features a smaller 13.8 gallon fuel tank designed for high city efficiency (42 MPG), while the 2.0L EcoBoost gas model has a larger 16.5 gallon fuel tank.
So says A. I.
And we have proof that the hybrid has a gas tank that can hold 16+ gallons.
On my '25 XL Hybrid the Distance to Empty is using more than 13.8 gallons.

1st 2 fill-ups were 14.2 and 14.8 gallons with ~50 miles to empty. Last was 16.4 gallons with 13 miles to empty. All at different gas stations.

Just a heads-up to anyone counting on a lot of reserve after 0.
That's very interesting.
There's not much data from 2025's.
But 2022's to 2024's were pretty consistent.

Here's my 2022 TODAY.
I went 20 miles PAST zero showing.

Proof of 14.63 TO FIRST CLICK with no Top Off.

Chops, you already knew the hybrid contained a larger tank because you it already read this particular post and liked it.
 
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Chops

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And we have proof that the hybrid has a gas tank that can hold 16+ gallons.


Chops, you already knew the hybrid contained a larger tank because you it already read this particular post and liked it.
Hi Glen,
Seems I was wrong. The EB &
Hybrid have different gas tank part numbers…

Look the same on the outside - but it is a mystery what differences lurk within!

Gas Tank Part Numbers:
SZ6Z-9002-A … EB
SZ6Z-9002-B … Corsair
SZ6Z-9002-C … Hybrid
SZ6Z-9002-D … Hybrid revised
 

Glen Baker LLC

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Hi Glen,
Seems I was wrong. The EB &
Hybrid have different gas tank part numbers…

Look the same on the outside - but it is a mystery what differences lurk within!

Gas Tank Part Numbers:
SZ6Z-9002-A … EB
SZ6Z-9002-B … Corsair
SZ6Z-9002-C … Hybrid
SZ6Z-9002-D … Hybrid revised
Thank you for researching and posting the part numbers. The hybrid revised part numbers could be just a different seal. It does not have to relate to size of the physical tank.
Who knows where the pressurization unit is. It could be external or internal?
Fact remains they still hold more than 13.8 gallons. 👍
 
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HeyBales

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The tanks are actually the same, on the pre-25MY anyway.
Ebay has some great photos from many angles - I posted in another thread.

Here are 2 tanks - notice the model numbers actually on the tank are the same. You can look at many listings for sale, and see the same thing.
The attached stickers say the difference - FT Shell for P758 FHEV or ICE. That probably makes the difference for the pump to insert, or something else.
But the tank is the same - they list both applications on the molded imprint.
NZ61 9002A
NZ68 9002B


https://ebay.us/m/KN5Byv - ICE

https://ebay.us/m/wyZQkb - FHEV
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