1989 FORD AEROSTAR Fuel System, Gasoline Problems

NHTSA RECALL 98V190000 CONCERNING FUEL SYSTEM STORAGE TANK ASSEMBLY: CONSUMER INTERMITTENTLY SMELLED A STRONG ODOR OF GASOLINE ON THE OUTSIDE OF THE VEHICLE. T CONSUMER EXAMINED THE GAS TANK AND FOUND THAT FUEL WAS LEAKING FROM THE TOP OF THE TANK WHEN IT WAS FULL. MANUFACTURER CLAIMED THAT THIS VEHICLE WAS NOT A PART OF THE RECALL.*AK

Mileage: 175,000

THE MANUFACTURER WAS REFUSING TO HONOR RECALL 98V190000 FOR FUEL TANK CRACKS BECAUSE THE WARRANTY PERIOD ENDED. *AK

Mileage: 160,000

CONSUMER STATES THAT THERE IS A CRACK IN THE FUEL TANK WHICH IS NOT ALLOWING THE CONSUMER TO FILL UP A FULL TANK OF GAS. CONTACTED DEALER AND THE DEALER STATED THAT THE WARRENTY PERIOD FOR THE RECALL HAS EXPIRED. MR

CONSUMER NOTICED GAS LEAK IN TANK.*AK

WHEN I WENT TO FILL UP WITH GAS, THE ATTENDANT CAUGHT MY ATTENTION AS I WAS ABOUT TO DRIVE OFF. A RIVER OF GASOLINE WAS POURING FROM BENEATH MY VAN. I TOOK IT TO MY MECHANIC WHO FOUND THE TANK HAD SPLIT ALONG THE SEAM WHERE THE TWO HALVES OF THE PLASTIC INJECTION MOULDINGS ARE JOINED TOGETHER. SINCE THIS INCIDENT I HAVE HAD AN IDENTICAL FAILURE ON MY OTHER VEHICLE OF THE SAME YEAR AND MODEL. I THINK FROM THIS, THAT IT'S PRETTY CLEAR THERE IS LIKELY TO BE A DESIGN OR MANUFACTURING FAULT IN THE GAS TANKS OF AEROSTAR VANS. NOTE, THE TANK ON ONE VEHICLE IS THE 16 GALLON VERSION, THE OTHER ONE IS THE LARGER 20 GALLON TYPE. SAME TYPE OF SPLIT OCCURRED ON EACH. I REGARD THIS AS A SERIOUS, LIFE-THREATENING FAULT. PLEASE NOTE MY ADDRESS DETAILS ARE FOR MEXICO, MY PHONE NUMBER IS [XXX] AND MY EMAIL IS [XXX]. *AK PARTS OF THIS DOCUMENT HAVE BEEN REDACTED TO PROTECT PERSONALLY IDENTIFIABLE INFORMATION PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

FUEL TANK HAS DEVELOPED CRACKS. WHEN FILLING TANK PASSENGER COMPARTMENT FILLS UP WITH FUMES FROM GAS. THERE IS CURRENTLY A RECALL FOR THIS, BUT THIS VEHICLE IS NOT COVERED. *AK

CONSUMER REPLACED FUEL TANK, DUE TO COMPONENT FAILURE, PRIOR TO RECALL (98V-190). CONSUMER IS REQUESTING REIMBURSEMENT. *CJ

THE GAS TANK WAS LEAKING FUMES, THEN WE NOTICED A PUDDLE OF GAS UNDER THE VEHICLE AFTER FILLING THE TANK. WE CONTACTED FORD AFTER READING ABOUT THE RECALL # 98MO3 REGARDING THE SAME PROBLEM WE WERE HAVING. INITIALLY THEY WERE GOING TO LET THE DEALER DECIDE IF WE FELL UNDER THE RECALL THEN DECIDED THAT SINCE WE WERE REGISTERED IN NJ NOT IN ONE OF THE STATES THEY LISTED THAT WE WERE NOT ELIGIBLE FOR THE RECALL. HAS ANYONE ELSE REPORTED THE SAME PROBLEM OUTSIDE OF THE STATES FORD LISTS? IF SO POSSIBLY THEIR RECALL SHOULD HAVE A WIDER AREA. ALSO WE DO NOT KNOW OUR VANS PREVIOUS OWNERS, POSSIBLY THEY WERE FROM ONE OF THE RECALL STATES. FORD ALSO SUGGESTED I CONTACT DMV TO FIND OUT WHO THE PREVIOUS OWNERS WERE. IT WAS ALSO SUGGESTED I HAVE THE VEHICLE REPAIRED AND SEND IN COPIES OF BILLS INCASE THE RECALL IS CHANGED TO COVER MY AREA.*AK

POSSIBLE RECALL COMPONENT FAILURE (98V-190) OF THE FUEL TANK PRIOR TO RECALL NOTIFICATION WHICH RESULTED IN VEHICLE FIRE. *MJS

AFTER RECALL REPAIR THE FUEL TANK FAILED RESULTING IN VEHICLE FIRE. NLM

CONSUMER CONTACTED DEALER IN REFERENCE TO RECALL 98V190000/ MANUFACTURER'S RECALL 98M03/ FUEL TANK CRACKS. VEHICLE HAS BEEN AT DEALER FOR OVER TWO MONTHS IN WHICH THE DEALER HAS YET TO DO REPAIRS. CONSUMER HAS CONTACTED MANUFACTURER. PLEASE PROVIDE ANY FURTHER DETAILS. *AK

STRONG FUEL VAPOR ODOR AND MINOR LEAKAGE FROM TOP PORTION OF GAS TANK AFTER FILL UP, DIMINISHES TO HARDLY NOTICEABLE WITH PARTIALLY FILLED TANK. THERE WAS A NHTSA RECALL NO. 98V190/FORD RECAL NO. 98M03 FOR VERY SIMILAR PROBLEM, BUT MISSOURI REGISTERED VEHICLES NOT INCLUDED ACCORDING TO YOUR MAP. DO NOT UNDERSTAND. CONTACTED DEALER AFTER SAW THIS RECALL NOTICE ON YOUR WEBSITE BUT SAID MY VIN NUMBER NOT INCLUDED IN RECALL. THIS IS SAME OR SIMILAR PROBLEM, AND IF AMBIENT TEMP RELATED, LIVING IN MID-MO NOT MUCH DIFFERENT THAN UPPER ARK. DO NOT UNDERSTAND. PLEASE EXPLAIN. *AK

AFTER FILLING UP THE FUEL TANK AND THEN DRIVING, FUEL WILL LEAK FROM TOP OF TANK. CONSUMER BELIEVES TANK IS CRACKED, AND THAT IS THE CAUSE OF THE LEAKAGE. *AK

HAD RECEIVED RECALL NOTICE #98V190000 & CONTACTED DEALER. SET APPOINTMENT. TOOK VEHICLE 2 DAYS LATER. MECHANIC LOOKED AT VEHICLE, BUT DID NOT REPLACE THE FUEL TANK. HAD CLEANED THE GROMMET ONLY. TOOK VEHICLE HOME. THE VEHICLE LEAKED FUEL OUT ON DRIVEWAY. OWNER REFUSES TO DRIVE VEHICLE DUE TO BEING A HAZARD. *AK

HAD RECEIVED RECALL NOTICE #98V190000 IN THE MAIL. CONTACTED DEALER & SET UP APPOINTMENT. TOOK VEHICLE ON DATE GIVEN. MECHANIC CHECKED FUEL TANK, BUT DID NOT REPLACE IT.

THERE IS A CRACK WITHIN THE GAS TANK WHICH CAUSES A LEAK. CONSUMER CAN SMELL GAS WHEN DRIVING. *AK

I PURCHASED THIS VAN TO ACCOMODATE MY FAMILY OF 7. THE A/C AND TRANSMISSION HAD BEEN REPAIRED BY LICENSED TECHNITIONS. THE GAS TANK HAS A SMALL 'HAIRLINE' CRACK THAT I HAVE TRIED TO PATCH MYSELF. I FEEL THE GAS TANK LEAK LOCATED AT THE EDGE OF THE TANK IS A DESIGN FLAW, BUT WHAT DO I KNOW? I JUST WANT MY WIFE TO DRIVE MY FAMILY TO AND FROM THEIR DESTINATIONS SAFELY. I HAVE LIMITED FUNDS FOR ALL THE REPAIRS. THANKS FOR LISTENING. REGARDS, TIMOTHY J. SHINN, PH#602-265-4323

CONSUMER RECEIVED RECALL NOTICE (98V19000). DEALER DENIED REPAIR DUE TO NO PARTS. HOWEVER, CONSUMER WAS ABLE TO OBTAIN THE PARTS FROM PEP BOYS AND REPLACEMENTS WERE DONE. *YC

DUE TO THE DEFECT OF THE FUEL TANK LEAKING INTO THE IGNITION WHICH CAUSED A FIRE, RESULTING IN TOTAL VEHICLE DAMAGE, PRIOR TO RECALL NOTICE (98V-190). *YC

WHILE DRIVING AT 35 MPH AND WITHOUT PRIOR WARNING, VEHICLE SHUTS DOWN. CONSUMER CAN SMELL GAS WITHIN THE VEHICLE WHEN TANK GETS HOT. DEALER STATES THE REASON VEHICLE IS CUTTING OFF IS DUE TO A LOSS OF PRESSURE. *AK

FUEL TANK REPLACED PRIOR TO RECALL. (98V-190)

FUEL TANK CRACKED/REPLACED PRIOR TO RECALL. (98V-190)

HAD STARTED TO SMELL GAS FUMES INSIDE VEHICLE. AFTER FILLING VEHICLE WITH GASOLINE & STARTED DRIVING, NOTICED FUEL DRIPPING AFTER VEHICLE. TOOK VEHICLE TO DEALER & INFORMED PARTS WOULD BE ORDERED. HAD MECHANIC REPLACE THE FUEL TANK. RECALL 98V190000. *AK

WHEN MUFFLER WAS BEING REPLACED ON THE VAN, THE FUEL TANK WAS FOUND TO BE LEAKING. THE FUEL TANK HAS NOT BEEN REPLACED. *AK

CURRENTLY THERE IS A RECALL FOR THIS TYPE OF FUEL TANK FAILURE. BUT THE RECALL ONLY DEALS WITH SOUTHERN STATES. THE GAS TANK WHEN FULL WILL DEPOSIT GAS ON THE GROUND, NOT FROM A NOTICABLE LEAK, BUT FROM THE EVAPORATION EFFECT AS DESCRIBED BY RECALL 98V190000. FORD IS REQUIRED TO REPLACE ONLY THE TANKS IN THE SOUTHERN MOST REGIONS OF THE COUNTRY. I FEEL THAT THE RECALL SHOULD BE MADE NATION WIDE. THE LOCAL DEALER SHIP SAYS A NEW TANK WOULD COST ABOUT $500.00 I FEEL IF IT HAPPENING HERE IN UPSTATE NY, (IT JUST BEGAN AT THE LAST FILL UP THE INSIDE OF THE VEHICLE HAS A STRONG ODOR OF GASOLINE INSIDE WHICH CAUSED ME TO DO SOME FURTHER CHECKING I NOTICE THAT AFTER SITTING IN THE GARAGE OVER NIGHT THERE A STRONG ODOR OF GAS IN THE GARAGE AND THERE WAS A DAMP SPOT UNDER THE TANK WITH SOME RESIDUAL GAS ON THE SHROUD PROTECTING THE TANK, THERE IS NO STEADY LEAK MORE LIKE AS A RESULT OF EVAPORATION TO THE UNDER SIDE OF THE UNDER CARRIAGE COLLECTING AND THEN DROPPING TO THE FLOOR. IF THIS RECALL IS NOT EXPANDED TO THE WHOLE COUNTRY, YOU WILL EXPERIENCE PROBLEMS IN THE NORTHERN CLIMATES THAT OCCURRED IN THE SOUTHERN STATES, CAUSING THE RECALL. IN THE SUMMER OF 1999. I HAVE LOWERED THE FUEL LEVEL IN THE TANK, AND THE VAN IS OFF THE ROAD. I WILL HAVE THE TANK REPAIRED BEFORE PUTTING ANY MORE GAS IN IT. BUT I THOUGHT YOU SHOULD KNOW, *AKAFTER SEEING THE RECALL NOTICE ON THE WEB. I MORE THAN LIKELY TRY TO HAVE THE TANK REPAIRED THAN COME UP WITH THE $500.00 THE FORD DEALER WANTS. I WILL ASK THE REPAIR SHOP FOR AN EVALUATION OF THE TANK AND THE CAUSE OF THE LEAKS IF IT HAS THE SMALL CRACKS DESCRIBED IN THE RECALL I THINK YOU SHOULD TAKE SOME ACTION.

FUEL TANK LEAKING GAS FROM FUEL FILLER PIPE,REPLACEMENT OF THE FUEL FILLER PIPE PRIOR TO RECALL (98M03), RECALL REFUSED DUE TO PRIOR REPAIR OF FILLER PIPE. YH

FUEL TANK LEAKING GAS FROM FUEL FILLER PIPE,REPLACEMENT OF THE FUEL FILLER PIPE PRIOR TO RECALL (98M03), RECALL REFUSED DUE TO PRIOR REPAIR OF FILLER PIPE. YH

DEALER REPAIRED VEHICLE AND REPLACED GASKETS AND OTHER PARTS. HOWEVER, WHEN DRIVING AT ANY SPEED VEHICLE STALLED. ALSO, DEALER REPLACED THE GAS TANK, AND GAS WAS STILL OVERSPILLING FROM TANK. DEALER HAD TO FIX THE GAS TANK AGAIN. VEHICLE IS CURRENTLY IN REPAIR SHOP FOR OTHER REPAIR PROBLEMS, AND DEALER REFUSES TO REPAIR VEHICLE. *AK

FUEL FILLER PIPE FAILED CAUSING FUEL TO LEAK.

WHENEVER PUTTING GAS INTO THE TANK, THE GAS TANK WILL BE FULL AND THE GAS WILL SPILL ALL OVER THE GROUND, AND THE TANK WILL INDICATE AS EMPTY. TANK WILL ONLY HOLD A CERTAIN AMOUNT OF GAS, BUT THERE IS SO MUCH GAS INTO THE TANK THAT IT WILL OVERFLOW. DEALER CAN'T DETERMINE THE CAUSE OF THE PROBLEM. *AK

GASOLINE WAS LEAKING FROM THE VEHICLE ,AND IF THE CONSUMER FILLS UP THE VEHICLE WITH GAS, THE GAS WILL COME OUT ALL OVER THE VEHICLE. CONSUMER CAN SMELL THE GAS COMING INTO THE VEHICLE WHILE DRIVING, AND THE DEALER CAN'T FIND THE PROBLEM. *AK

REPLACED THE ORIGINAL GAS TANK 9/8/95. I REPLACED THE REPLACEMENT TANK 9/11/98. THE TANK FAILED AT THE TOP OF THE GAS TANK JUST LIKE THE ORIGINAL FAILURE. SENT LETTER REQUESTING REIMBURSEMENT TO FORD,SEPT. 98. INFORMED OF RECALL,DECEMBER 98. FORD DOESN'T RECOGNIZE THIS DEFECT BECAUSE IT WASN'T INSTALLED BY A FORD DEALER. SINCE THE FAILURE WAS THE SAME AS THE INITIAL FAILURE FORD SHOULD BE RESPONSIBLE. THERE IS NO AFTER MARKET GAS TANK AVAILABLE, YOU MUST PURCHASE FROM FORD SERVICE DEPARTMENT. MECHANIC IS A CERTIFIED GOODYEAR MECHANIC AND HAS OVER 25 YEARS OF EXPERIENCE.

CONSUMER REPORTING AN ONGOING PROBLEM WITH ENGINE ACCELERATION INTERMITTENTLY APPROXIMATELY SIX MONTHS. PROBLEM STILL OCCURRING. DEALER WAS NOTIFIED AND REPAIRS/INSPECTION WAS MADE CONTINUALLY, BUT THE PROBLEM WAS NEVER RESOLVED. *AK CONSUMER STATES VEHICLE IS EXPERIENCING ELECTRICAL PROBLEMS AND CAN SMELL SOMETHING LIKE WIRES BURNING, CONSUMER STATES THAT THE RADIO, FAN BLOWER, AND DASH LIGHTS GO ON AND OFF, AT TIMES THE RADIO WILL NOT WORK AT ALL, BATTERY FAILED AND WAS REPLACED, LOW OIL SENSOR FAILED AND WAS REPLACED. VEHICLE HAS EXPERIENCED SEVERAL BRAKE PROBLEMS, BRAKES PULSATE, MASTER CYLINDER LEAK, PROPORTIONING VALVE LEAK, BRAKES GRAB, AND WERE NOT STOPPING THE VEHICLE. SEVERAL ENGINE RELATED PROBLEMS, CONSUMER STATES THE ENGINE WAS NOISY, OIL WAS LEAKING FROM BOTH SIDES OF ENGINE, THE THERMOSTAT, GASKET SEAL, MAIN SEAL, REAR MAIN SEAL, PAN GASKET, BELTS, AND OTHER ENGINE COMPONENTS HAVE BEEN REPLACED. THE LEFT DOOR CORRODED AND RUSTED. FUEL FILTER WAS REPLACED, EXHAUST SYSTEM WAS REPLACED, IAC AND THROTTLE BODY WERE REPLACED, CONSUMER STATES SHE WOULD HAVE TO CONSTANTLY KEEP FOOT ON BRAKE DUE TO HIGH RPMS AND LOUD WHINING, CONSUMER STATES VEHICLE WOULD ACCELERATE SUDDENLY IF FOOT WERE OFF THE BRAKE, THERE WERE TIMES WHEN THE BRAKES WERE NOT STOPPING VEHICLE. RIGHT FRONT TIRE SEPARATED, CAUSING STEERING WHEEL TO WOBBLE, FRONT BEARING NEEDED PACKED, RIGHT REAR AXLE WAS LOOSE. DIFFERENTIAL CARRIER ASSEMBLY WAS OUT, CAUSING A LOUD TICKING AND THUD NOISE. AIR CONDITIONER WAS BLOWING HOT AIR, THE HEATER MODE SELECTOR IS SLOW TO RETURN FROM THE VENT WHEN CHANGED. OUTER TIE ROD ENDS NEEDED REPLACED. *SLC

NHTSA RECALL # 98V-190, FUEL TANK CRACKS. CONSUMER VEHICLE WAS NOT UNDER THIS RECALL, VEHICLE EXPERIENCED SAME PROBLEM, AND HAD TO REPLACED FUEL TANK AT CONSUMER'S EXPENSE. DEALER NOTIFIED. *AK

GAS TANK SECURED BY METAL BRACKETS UNLINED WITH FOAM, WHICH RESULTED IN RUBBING ONTO THE PLASTIC GAS TANK CAUSING FUEL LEAK FROM SPLIT IN TANK. (DESIGN FLAW).

GAS TANK FAILED RESULTING IN LEAKING.

GAS TANK LEAKING RAW GASOLINE ONTO THE GROUND. *AK

GAS TANK CRACKED AT FILLER NECK.

VEHICLE SUDDENLY BEGAN LEAKING FUEL DUE TO A CRACKED FUEL TANK.

FUEL TANK CRACKED.

OWNER STATES UPON FILLING VEHICLE WITH GAS HE SMELLED FUMES AND THAT HE HEARD THAT THEIR WAS A RECALL FOR A CRACKED FUEL TANK, OWNER STATES THAT HE IS HAVING THIS PROBLEM, NOT PART OF A RECALL. *AK

REPLACED THE GAS TANK BECAUSE THERE WAS A CRACK IN THE TANK WHICH WAS CAUSING A LEAKAGE FROM THE TOP. *AK

FUEL TANK LEAKING WHEN FILLED HALF WAY. *AK

GAS TANK CRACKED.

CONSUMER REPLACED FUEL TANK BECAUSE OF CRACKS. *AK

PLASTIC FUEL TANK DEVELOPED CRACKS IN VARIOUS LOCATIONS IN THE UPPER AREAS, CAUSING GASOLINE LEAK. *AK

THE FUEL TANK CRACKED, CAUSING A FUEL LEAK. *AK

THERE IS A CRACK IN THE FUEL TANK, PURCHASED TRUCK NEW . TT

WHEN FILLING THE FUEL TANK ABOVE 3/4 FULL. THE TANK HAS A STEADY LEAK.*AK

THE TRUCK PARKED IN GARAGE FOR TWELVE HOURS TRUCK CAUGHT ON FIRE BURNED GARAGE DOWN . TT

SEALS ON THE FILLER TUBE ARE FAULTY, CAUSING A LEAK. TT

DEFECT IN THE FUEL TANK THE FUEL TANK CRACKED/SPLIT. TT

SPLITING SEAM RESULTED IN FUEL LEAKAGE FROM GAS TANK TO BLOW PASSED EXHAUST MANIFOLD. CREATING CONDITION FOR POTENTIAL FIRE. TT

PART E79Z9002A. PLASTIC RECYCLED TANK CRACKED FUEL LEAKAGE AND POTENTIAL FIRE. DEALER STATES IT WILL NEED REPLACEMENT IN FOUR YEARS. OWNER HAS DEFECTIVE TANK.

BROMITE AT GAS TANK FILLER NECK BROKEN, CAUSING GAS TO LEAK WHEN TANK IS FULL. *SKD