7.3 liter diesel engine stalling. Fuel pump and fuel filter replaced;fuel tank removed and cleaned; silver paint flakes were found blocking the fuel pickup. Tank was re-installed and problem re-occurred within 100 miles. Van was taken to local Ford dealership and tank was removed again. Silver paint flakes were found blocking the fuel pickup line again. The service technician determined that the fuel tank liner was de-laminating, and the fuel tank needed replacing. I have the defective tank in my possession. This was a dangerous defect that caused engine stalling in heavy traffic, endangering myself and other motorists behind and beside me. This was also an expensive and time consuming repair, resulting in loss of use and rental expenses.

- Pahoa, HI, USA

2000 Ford E-350 econoline diesel serial [xxx] was subject to recall due to leaking diesel fuel from 35 gal. Tank. Ford claims recall was performed for previous owner. Tank is leaking again. Repair was not suffecient to elimiate failure. Mileage at second leakage 99,000 to present. Information redacted pursuant to the Freedom Of Information Act (FOIA), 5 U.S.C. 552(B)(6)

- Valparaiso, IN, USA

While driving on the freeway my van lost almost all power, dropping from 65 miles per hour to 25 miles per hour. I had to immediately try and move over to the slow lane. I quickly lost all power and my stopped running. Part of my left rear was slightly out in the traffic lane. I called a tow truck to have my van towed to the Ford dealership that maintains my van. The dealer informed me my fuel tank had "delaminated", the inside coating had deteriorated and had clogged the entire fule system and that the tank, filters, pumps and all lines had to be replaced. I understand moving parts failing, but I have never heard of a fuel tank failing except through puncture or exterior deterioration through rusting. Repairs will cost several thousands of dollars. The dealership mechanics say this has occured on a number of occasions with Ford diesels, ranging in mileage from 30,000 to 200,000. The Ford Motor Company knows of the problem but has said the cause is from using additives or from the fuel. I do not use additives and have used only proper fuel from reputable companies. I approached Ford Motor Company for assistance in covering the cost of repairs but was told they are not responsible. This is a known problem caused by either a poorly engineered or incorrectly applied interior tank lining that fails with no warning and causes either total or near total loss of power. If this occurs on a crowded, fast moving freeway, the danger is obvious. I was lucky to have been driving at a time of day when there was little traffic. Ford Motor Company refuses to admit there is a dangerous situation with their diesel fuel tank lining material. I now am having a new tank being put into my van, but what is there to ensure me that the same situation will not happen again? it is not mileage dependent according to those who should know, the Ford mechanics. Such a situation is not only unsatisfactory, but extremely unsafe for both myself and others on the road.

- La Jolla, CA, USA