2022 Hybrid Fuel Tank Leak

[Glen Baker LLC]

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!

And if indeed the Maverick hybrid fuel tank is lacking an internal bladder. Any type of "small" leak is exacerbated by the positive pressure within the fuel tank.

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[Chops]

And if indeed the Maverick hybrid fuel tank is lacking an internal bladder. Any type of "small" leak is exacerbated by the positive pressure within the fuel tank.

I’m guessing the internal baffling/components in the Hybrids gas tank, along with the smaller amount (13.8gals) of gas allowed - is less expensive than a bladder system to manage pressure changes?

The EB, which has looser EPA standards than the Hybrid, does vent the pressure through the charcoal canister more often than the Hybrid does. Hybrid keeps it “bottled up”.

And while both the EB and the Hybrid suffer from tank leaks and overfilling problems - the Hybrid seems to be more susceptible to these issues.

 

[Glen Baker LLC]

I’m guessing the internal baffling/components in the Hybrids gas tank, along with the smaller amount (13.8gals) of gas allowed - is less expensive than a bladder system to manage pressure changes?

The EB, which has looser EPA standards than the Hybrid, does vent the pressure through the charcoal canister more often than the Hybrid does. Hybrid keeps it “bottled up”.

And while both the EB and the Hybrid suffer from tank leaks and overfilling problems - the Hybrid seems to be more susceptible to these issues.

Well you can actually fit more gas in the hybrid gas tank than what Ford quotes.
Several members on the forum have put more than 15 gallons in their tanks.

https://www.mavericktruckclub.com/f...-16-5-gallon-tank-tested-and-confirmed.25173/

 

[HeyBales]

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.

Am I seeing that correctly - looks like the tube connection is higher up the side.
Besides the pretty blue, which looks like a very different insert than current one.

Now Glenn - don't go crawling out on your driveway!
Someone likely has a picture already.

 

[Chops]

Well you can actually fit more gas in the hybrid gas tank than what Ford quotes.
Several members on the forum have put more than 15 gallons in their tanks.

https://www.mavericktruckclub.com/f...-16-5-gallon-tank-tested-and-confirmed.25173/

I know you can. But should you?

“Bladder” tanks are notorious for not letting you overfill past a certain point. Can’t “top off” a bladder style tank.

By overfilling your hybrid past 13.8 gallons you are defeating the purpose of the baffles etc to keep pressure lower? Just asking for leaks & soggy charcoal?

 

[Glen Baker LLC]

Am I seeing that correctly - looks like the tube connection is higher up the side.
Besides the pretty blue, which looks like a very different insert than current one.

Now Glenn - don't go crawling out on your driveway!
Someone likely has a picture already.

Damn I was just under my truck doing an oil change.
I was going to mention I can never keep things absolutely clean.
I started using puppy pads underneath the drain pan.
Now, I just use underpads. They're absorbent they're better than newspaper and a they cost less than newspaper.

Oh well. Here is a picture of mine anyway.

 

[HeyBales]

I know you can. But should you?

“Bladder” tanks are notorious for not letting you overfill past a certain point. Can’t “top off” a bladder style tank.

By overfilling your hybrid past 13.8 gallons you are defeating the purpose of the baffles etc to keep pressure lower? Just asking for leaks & soggy charcoal?

It's more the other direction, not topping off.
Since the fuel is added under the level causing some pressure to be built up, and incoming hose blocked - can't really fill up past certain level.

It's why the PID for fuel tank level states the evap pressure tests cannot be run below or above a certain %. I have a picture somewhere showing that.
Above the upper limit - tank inlet cut off - can't pressurize.
Below the lower limit - I'm guessing too much tank available - pump not designed for filling that much space to pressure needed.

This is more about safely using fuel below where the truck says you have no miles to empty.
And still many more gallons left - some of which can't be touched due to the fuel pump in it's little well. But still a couple available.

 

[HeyBales]

Damn I was just under my truck doing an oil change.
I was going to mention I can never keep things absolutely clean.
I started using puppy pads underneath the drain pan.
Now, I just use underpads. They're absorbent they're better than newspaper and a they cost less than newspaper.

Oh well. Here is a picture of mine anyway.

Hmm - does it appear just a little lower on older style?
I can't tell, probably because it's not.

 

[kbuchle2]

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

Best of luck to you, please post back here on what you find out. Exact same leak in the exact same location as mine. It took me about a month to get it all sorted, and when it was all said and done I got a new tank that has a new part number and a totally different design.

 

[kbuchle2]

Am I seeing that correctly - looks like the tube connection is higher up the side.
Besides the pretty blue, which looks like a very different insert than current one.

Now Glenn - don't go crawling out on your driveway!
Someone likely has a picture already.

I need to get the truck up on the lift to see it a little easier and I can post back here with what I can find out. But it has a new part number and has many visual differences that the dealership shared with me when I picked it back up. I did not see the inside of the tank as has been talked about here but visually from the outside it is very different.

 

[AVC]

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

 

[AVC]

Best of luck to you, please post back here on what you find out. Exact same leak in the exact same location as mine. It took me about a month to get it all sorted, and when it was all said and done I got a new tank that has a new part number and a totally different design.

*Totally* different? Photos?

 

[First Sergeant]

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.

Interesting read, thanks!

 

[silvy]

Best of luck to you, please post back here on what you find out. Exact same leak in the exact same location as mine. It took me about a month to get it all sorted, and when it was all said and done I got a new tank that has a new part number and a totally different design.

Dealer called and said there is no fuel leak....I could have guessed that. Dealer claims that the liquid around the tank connection hose is multipurpose lube.

I explained to him that it occurs after the truck has been driven about 1 mile on battery only, and put back in the garage. Which goes along with what Glen was saying in an earlier post about the pressurized tank.

I will have to wait until the garage smells again and crawl under and take another picture.

 

[kbuchle2]

Dealer called and said there is no fuel leak....I could have guessed that. Dealer claims that the liquid around the tank connection hose is multipurpose lube.

I explained to him that it occurs after the truck has been driven about 1 mile on battery only, and put back in the garage. Which goes along with what Glen was saying in an earlier post about the pressurized tank.

I will have to wait until the garage smells again and crawl under and take another picture.

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.

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