I was driving home from work and my Ford Expedition started hesitating. I was driving on winding West Virginia road at the time. Vehicle stalled out after hesitations. I was able to restart and bring the vehicle back to speed. It hesitated several more times. In town when starting from a stop it stalled out twice more. Stalling occurred as I pressed on the gas pedal. I brought it in to the dealer. They changed the ignition coils. As I pulled out of the dealer it stalled out again. I was in the middle of the intersection when this occurred and was very lucky that this did not cause an accident. I brought it back to the dealer. They had to change out the fuel pump. The side the electrical wires on the pump had melted and were making intermittent contact causing the hesitation and stalling. This could have very easily caused an accident.

- Acworth, GA, USA

Fuel pump arced internally inside the fuel tank connector shows signs of open spark.

- Colusa, CA, USA

Backing out of my driveway, the truck died and would not restart. I had it towed to my mechanic and was told the fuel pump was bad. When he removed the pump from the gas tank, my mechanic noticed the electrical wires had burned up. He stated that he was surprised it didn't start a fire or explode. I cannot find another fuel pump anywhere. Ford says they don't know when any will be available, maybe November. I am stuck making payments and keeping insurance on a vehicle that may never run again.

- Pearcy, AR, USA

Our family drove our Expedition el to hilton head island, SC. After stopping to rent some bikes we went to start our vehicle and it would not start. After having it towed to a local shop we were told that our fuel pump was burned up and that they would order a new pump. The next day they called back to inform us that there are no fuel pump's available for the Expedition el 131" wheel base and they have no idea when they will be available and Ford would not give them any information. We contacted Ford and they would not help us unless we transferred the vehicle to a Ford dealership. We did that and the Ford dealership told us the exact same thing. After trying all week to find a fuel pump or try to use the shorter version there was no way to find one. We ended up having to rent a car and drive it back 1000 miles to Michigan. When we got back to Michigan and contacted Ford they once again said it is not their fault, the car is not under warrantly and sorry for the inconvenience but they owe us nothing and they can't help us. When I asked when there would be fuel pumps available they never responded. I located a used fuel pump in Canada and shipped it to the Ford dealership. I then flew back to hilton head and drove it back. The first time we stopped the car to get something to eat the car would not start. I finally got it started and never shut the car off again from SC to Michigan - even while pumping gas and never let the tank get beow 1/2 a tank. The car now jerks and the fuel pump is about to go again. Every time I get in the car I am afraid it is just going to stop working and I will get in an accident. So far it has cost us over $2000 to just get the car back home after all the extra costs and Ford will not tell us anything or when any will be available. They furthermore said they work closely with NHTSA and there are no issues with this part.

- Hudsonville, MI, USA

The fuel pump burned up. We have been waiting for almost a month now for a replacement. The word on the internet is that Ford is not even manufacutring the part now because there is a problem with it.

- Cordova, TN, USA

This is my wife's vehicle and she was taking my kids and a few from the neighborhood as well as my disabled father to sonic to get some icecream. I was away for a baseball tournament with my 9 yr old and received a call that the car would not start. I had to leave and miss my sons game to make sure my wife was ok. Well after trying everything I could and still could not get it started I had it towed to a garage. They dropped the tank and found that the connectors on the pump were melted and stated this could have caused a fire. Now I was told by a Ford dealer that the were remaking the pumps as they knew of this issue. So if you know of this issue and don't advise the public I feel they are liable for any damage or claims that this issue may cause. The worst part is when I tried to get a new fuel pump for this I was told they were on back order and would not be available until Aug 5 2013. So that is 2 months without a second car, and makes it very hard to make it to work ontime. Ford then stated that I dose not show that I ordered a part and they could not help unless I ordered the part and then they would see about the problem. Now a recall should be looked into for this as melted wires in a secured gasoline tank. That sounds more like and ied waiting to happen. I would appreciate you looking into this. [xxx] information redacted pursuant to the Freedom Of Information Act (FOIA), 5 U.S.C. 552(B)(6).

- Arlington, TX, USA

While driving on the interstate or fwy at about 55-60 mph - I start to increase in speed, while going with the flow of traffic my Expedition eddie bauer model spurts/hesitates/loses power "but never cuts off" every time before the speed increases. We took it to the Ford dealer several times an they are unable to determine what is wrong with the vehicle. The Ford dealer told us they can't do not about it until the engine light comes on. We suggested to the Ford dealer that it maybe the fuel filter or O2 sensor but they told us this model vehicle does not have a fuel filter and our O2 sensors are good. My issue is why should I have to wait till the vehicle breaks down when it does this all the time.

- Columbia, SC, USA

I was driving my 2007 Ford Expedition el on the highway and it started sputtering. As I started to change lanes to exit the freeway I lost all power. Luckily right at the end of the freeway exit ramp was a shopping plaza. I coasted into the plaza then my husband, 3 kids and 2 strangers pushed me safely into a parking lot. I had the car towed to my local Ford dealer on 6-10-13. The diagnosis was I needed a new fuel pump. After several days of telling me it was coming. The dealership confessed that the part was on national back order and expected delivery was some time after August 4th 2013. My warranty will only cover 8 days of a rental. My local dealer will not give me a car nor with Ford corporate. My dealer also mentioned that other model Ford have fuel pumps on backorder like the Taurus and Explorer. I am wondering if this is design flaw in general with the Ford fuel pumps and they are trying to keep it from going to a recall. One post I saw the guy said his dealer told him there were $1286 Expedition el fuel pumps on back order. This is not right. I will be without a car for 56 days. Of those 56 I can only get a car for 8. what am I supposed to do? Ford needs to fix this for free as well as give everyone a rental until their car is fixed.

- Kingwood, TX, USA

I was traveling down the highway and was coming up to a stop light and the vehicle died out. I was able to get the vehicle started and shortly after that, I was traveling down the highway again and while I was speeding up to about 55 mph the vehicle shut down again and I was barely able to get away from the traffic around me and get the vehicle pulled over to the side of the roadway. I attempted restarted the vehicle and it could not get the vehicle to restart, luckily I work on vehicles myself and determined that the problem was a fuel pump issue. I tapped on the fuel tank, got the vehicle started and was able to drive me and my family all the way back home, but the vehicle was driving rough and no lights came on indicating I had a problem, before or after. I will get the vehicle tested on to see what would have caused it. After reading a great number of these complaints, the problem seems to point at and is clearly indicating it is the fuel pump!! we were very lucky that the vehicle didn't explode because the fuel pump wires have a tendency to melted on the fuel pump. I doubt Ford would pay for this fuel pump failure it seems to be a common problem when you look on-line.

- Mineola, TX, USA

Vehicle experienced a no start. Was towed to Ford dealership for repair; diagnosed as failed fuel pump. Fuel pump was replaced and old pump returned to me. The old pump has a melted and scorched electrical connector where the wiring comes into the pump motor, which in the presence of gasoline vapors, had the potential to be disastrous. I noted several other similar NHTSA complaints regarding this vehicle in this model year. Pictures available upon request.

- St. Augustine, FL, USA

The fuel pump went out on our 2007 Ford Excursion while being operated. When examined, the mechanic stated that we were lucky the vehicle didn't catch fire or blow up since the wiring burned out on the fuel pump in the fuel tank. (I have pictures of the fuel pump that was removed). Someone needs to investigate these fuel pumps and determine what caused the wiring to burn up.

- Bruceton, TN, USA

2007 Ford Expedition 119 wb. My fuel pump stopped working. When I pulled it out of the gas tank I was shocked. One connection had been burned and melted away. I would think that anything getting that hot to melt the plastic and have burn marks on it inside a gas tank would be really bad. I have pictures.

- Las Vegas, NV, USA

I have a 2007 Ford Expedition el. I lease a 4000 sq. Ft. garage where I'm working to open my own dealership. On the morning of February 18, 2010 around 3am the Expedition caught on fire all by itself. It started on the engine and worked its way back until the firefighters arrived and were able to put it down in a timely manner. The Expedition is a total loss. The 2008 F350 crewcab dually I had parked next to it had some damage to the driver side and also extensive damage to the ceiling and insulation of the building. The police crime scene investigator mentioned right off the bet that these cars have a cruise control recall and it is common to many of them to catch on fire all by itself. I did some research online and found two major problem with these cars involving the risk of fire: A recall for the fuel rail assembly and a problem with the speed control deactivation switch being powered at all time and resulting in fire under certain conditions. Since my lease started on February 1st and I'm in the process of opening and registering the business, I had no insurance all the time. The insurance of the garage's owner will cover the damage on the building but none of my car and truck damage. On top of loosing my car, my business will be shut down for about two to four weeks until the insurance get all paperwork and claim settled and owner gets the place all fixed up. All that's left for me is to find a way of getting Ford to acknowledge and take responsibility for the default vehicle - not only mine, but the tens of thousands - they have driving on the streets putting at risk many homes and lives. That is pretty scary taking into consideration that there's many people that lost everything due to this fire and I was lucky enough not to loose everything I had.

- Orlando, FL, USA