jlupicki

The bill shows that this was a purge valve. Brought in the TSB printed for them... They charged me $90 to diagnose. Replaced the valve for $45 and the valve assembly for $90. Part number 9L3Z*9E730*C

My mileage was 38127 when I got the work done. Out of warranty...

texasgator

Looks like it was designed that way - I just took my truck in at 38,5xx miles. They say they have to replace the purge valve because it wasn't releasing the pressure in the gas tank, so it sucked in on itself, causing the fuel pump to be damaged and I believe the sending unit.

Luckily, the guy at Ford called the guy at my extended warranty company, and they worked it out. Ford is covering some of the repairs, the extended warranty is covering the rest. I'll only be out a $100 deductible.

jlupicki

Truck is back in the shop for the 3rd fuel sending unit. Also having them redo the slip yoke clunk issue.

Interesting to note that they didn't believe that the fuel gauge was acting up again. I had to bring the truck in and pick up a service tech so he could go with me to see how I put gas in my truck. I guess they thought I was doing it wrong. This is shaking my faith in Ford. At what point does this truck fall under the lemon law? I have a huge file full of warranty work and work that I had to pay for.

Just want to reiterate that I believe TSB's should be free. This is an issue that the factory has found a solution for. If there was no issue there would be no TSB. End rant...

jlupicki

Well it turns out that some purge valve caused the fuel pump to collapse my fuel tank. Now they have to replace the purge valve (again) and the fuel pump since when the tank collapsed it bent the fuel level sending unit and some other bracket on the pump.

Somehow all this relates to the fuel gauge not reading correctly. So all of those threads concerning parking the truck on an angle and having inaccurate fuel gauge readings probably had this bad purge valve and it caused all this other stuff.

This is an expensive fix if not covered by some sort of warranty.

Now I wonder if my tank is more prone to collapse. Since it did this once or many times the tank is probably weaker.

Sucks...

texasgator

Yep, that's exactly the problem they said was on my truck. Ford covered part of it under factory warranty, and my extended warranty covered the rest. I'm worried about my gas tank too- they didn't replace it.

bubbuh

'09 F150 did the same thing. Dies after filling up. Fuel indicator gauge will not read full when the tank is full. Indicator goes down rapidly at some point. Code shows 02 sensors bad. The code is bogus. The canister purge solenoid is bad or the wiring going to it is bad or a vacuum/vent hose has collapsed or collapses.

The issue of the gauge reading incorrectly is this: The fuel pump basically sits on the bottom of the tank. The float assembly is attached to the pump. There are two stainless steel rods which are attached to the fuel pump and stick straight up to the fuel pump access panel at the top of the tank. If the solenoid is not working properly, a huge vacuum developes and will suck the bottom of the tank up and bend the rods. So now, instead of the pump/float mechanism sitting on the bottom of of the tank, it has moved up and the float now indicates less than full.

As you are driving and the indicator suddenly goes down, it is because the tank is deforming under vacuum and moving the pump/float up (which has the effect of lowering the fuel level). If you stop and insert the plastic full spout and in the filler opening, you will hear a whoosh as the pressure equalizes. The tank may or may not spring back to its original size. Mine does not. When I fill the tank, the weight of the fuel will expand it back to almost its original size, but not enough to show a full tank.

The issue is not a fuel pump problem. It is not an O2 sensor problem, and it is not a charcoal canister problem. Ford knows what the problem is. I believe the problem is the canister purge solenoid or the wiring to it.

kee

I am having a similar issue with my 2010 Ford Expedition. It will crank but won't start after filling up and it also dies randomly while driving through town but have had no issues with the fuel tank level indicator. I have had it in to the dealership 3 times now for the same issue and they keep sending it back home because no codes are coming up when scanned.

I initially was thinking fuel pump control module or the fuel pump itself but sounds like my issue be this purge valve as well? If so does anyone have the TSB number so that I can print it off and take it to the dealership.

I am very frustrated with Ford at the moment. If there is a TSB for this issue shouldn't the service techs be aware of it with the symptoms I have described and be able to recommend a solution without solely relying on their code scanners.....?

Wanted33

Welcome to the forum. Sorry I don't know the TSB number, but you can do a search and it should pop up. Or you could talk with the service writer, maybe they will look it up for you. There are so many TSB's that these tech have to deal with they can't possibly know all of them, and I have found if you go in with a little info to help them things usually get done. Good luck

CATMAN1979

So far I've had all the problems seen so far. I've been very unhappy with this truck the day the Factory Warranty Ran Out. The gas gauge never reads full anymore the max it goes is 7/8ths of a tank. Used to be pinned above full. Now when it say's there are 0 miles left, I still have 14 gallons in the tank. The truck has stalled on me 3 times. Once when coming off the Highway I stopped at the red Light and it stalled. The second time it would not start after filling up. It started and then stalled. The third time I pulled into a parking lot and had to slam on the brakes when someone pulled out in front of me and it stalled again.

This should not be happening with a 5 year old vehicle. This is also very dangerous and I am filling a complaint with the National Transportation Agency.

Popx3

I've had all the problems on my 2010 F150 Platinum 5.4L 3V, 100K miles, except for the gas gauge issue. Won't start after filling up with gas, and stalling out at stop signs, lights, or even slowing down to turn a corner. I just ordered a new Vapor Canister Purge Valve, Ford Part #9C915 (CX-2447) and plan on installing it myself. I saved a bunch on Amazon:

https://www.amazon.com/Motorcraft-CX-2447-Vapor-Canister-Purge/dp/B009B5T22M/ref=sr_1_1?s=automotive&ie=UTF8&qid=1485884002&sr= 1-1&keywords=ford+CX2447[/url]

I also found these two youtube videos VERY helpful:
https://www.youtube.com/watch?v=S6dsQoq73aE[/url]
https://www.youtube.com/watch?v=Eu1vlIOQOyk[/url]

I'll post the results of the repair as soon as I get it installed and drive it a few miles.