HYBRID ONLY Fuel line issue

[SafetyGuy]

So I went out to look under my 2025 Hybrids hood, again.

At the point where you only have the thin plastic sleeve, I have a thick synthetic material protective sleeve...)my line tag isn't orange, it is white).

A change made as Ford may have found the area needed more protection?

This makes me go Hmmmmm, some more.

The synthetic piece is zip tied on OVER the thin plastic shielding (the belt and suspenders method) so I wonder what is going on and why mine is extra shielded, and earlier trucks are not....maybe there should be a recall for the extra protection to be added if this was the fuel line damage and leakage area?

Again, I say hmmmm....

So many questions, eh!

Andy

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[Glen Baker LLC]

Here's my 23 for comparison.

Here's the OP's 22 with the fuel leak.

 

[SafetyGuy]

Thank you, Glen

I will assume @rclee has a 2022 and yours is a 2023, also with the orange tag and 1 layer of protection over the fuel line of interest.

It is missing the synthetic sleeve over the suspect area.

And I do note that your line in the area of question is unsullied...no holes or indication of damage.

We do not know yet if this was the precise area where fuel mist was releasing from, we can only assume at this point till we receive clarification.

Cheers,

Andy

 

[SafetyGuy]

My continuing thoughts, as we await any further feedback from the OP.

In the front of my mind is the thought that if this hazardous situation (vaporized fuel spewing into the potentially hot engine bay) did happen with no exterior forces acting upon the line, is the saving of the subject failed fuel line for investigative purposes.

If the dealership (involved technician as well as the job person behind the desk) show no interest in why this happened, parts will be changed and quickly disposed of. Fix it up and get it out, which is normal for a repair facility.

I can only think of 3 things that could lead to this fuel line leaking:

1-was the line damaged during the installation/assembly and time (I am assuming the OP's truck is a 2022) took its toll resulting in a small fracture and vaporized fuel escaping into the engine bay,

2-was any maintenance carried out on the line or in the area where accidental damage occurred and eventually led to the fuel vapor leak,

3-a design fault, by Ford as to the construction of or quality/specifications of the plastic fuel line that is under pressure and time, heat etc has taken its toll resulting in a hairline fracture allowing the fuel release.

It is interesting that early models of Mavericks have no sturdy 2nd layer of shielding, while my 2025 model does.

And now we wait...

Andy

 

[icegradner]

My 22 also looks the same as Glen's, but not as clean. No sign of damage after almost 4 years.

 

[SafetyGuy]

My 22 also looks the same as Glen's, but not as clean. No sign of damage after almost 4 years.

Thank you for your photo, @icegradner

So far 2022-2023's are fitted identically.

If an 2024 Maverick Hybrid owner takes a pic and posts it we will have each earlier year represented.

If a 2026 Maverich Hybrid owner could take and post the same fuel line for our edification, that would be appreciated as well!

Enquiring minds want to know...

Another thought I have had is that the extra synthetic piece my 2025 has over the line could be a heat shield as well.

Repeated excessive heat cycling could be hard on the plastic lines over a long period of time.

Andy

 

[El Kabong]

So far 2022-2023's are fitted identically.

If an 2024 Maverick Hybrid owner takes a pic and posts it we will have each earlier year represented.

If a 2026 Maverich Hybrid owner could take and post the same fuel line for our edification, that would be appreciated as well!

2026 hybrid checking in:

 

[SafetyGuy]

Wonderful! Another year covered off, @El Kabong!

So, was 2025 the start of the extra synthetic line protector/heat shield, or did it occur in the 2024 model year?

We all can figure out ourselves that additional items that add cost or time are never added by manufacturers unless it was really needed, they did add this extra piece to shield that fuel line.

Come on, unknown 2024 Maverick owner! We showed you ours, how about, ah, popping your hood so we can look inside!

Ah, cheese and crackers...that sounds a little creepy...sorry about that.

Just trying to add a bit of levity.

Andy

 

[icegradner]

The strange part is the area with extra shielding (25?+) doesn’t seem to be near a major heat source. Looks to be near a sensor, or maybe a pump of some kind.

 

[rclee]

OK guys, I am back (yard work) the extra insulation/protection that Andy has is exactly where the leak was. The vapors from the fuel was in ther area of the EGR. The fuel was everywhere on top the engine. It was puddled, I wish I took a picture of it. Maybe the vibration of the engine caused the breach. That may be why they changed the fuel line on the 25 26 Mavericks. Too bad I don't have the truck to take extra pictures.

I will keep you informed of what happens next.

 

[SafetyGuy]

OK guys, I am back (yard work) the extra insulation/protection that Andy has is exactly where the leak was. The vapors from the fuel was in ther area of the EGR. The fuel was everywhere on top the engine. It was puddled, I wish I took a picture of it. Maybe the vibration of the engine caused the breach. That may be why they changed the fuel line on the 25 26 Mavericks. Too bad I don't have the truck to take extra pictures.

I will keep you informed of what happens next.

Thanks, for finishing the yard work and getting back to us!

I have had too much time to think, as I was doing yard work as well, till it got too hot for me outside.

I still feel if you haven't done any work in the area, that this should be reported to your NHTSA so they can do an investigation. Let your Ford dealer know that it has been reported.

If NHTSA gives you a report number, I would share that with your Ford dealer ASAP, so they keep the parts if needed for the investigation.

It doesn't cost you anything and you could save another Mav or even another life, potentially.

Every older model Maverick may need this fuel line cover, for all we know.

Have a great day,

Andy

 

[Waterick]

Wonderful! Another year covered off, @El Kabong!

So, was 2025 the start of the extra synthetic line protector/heat shield, or did it occur in the 2024 model year?

We all can figure out ourselves that additional items that add cost or time are never added by manufacturers unless it was really needed, they did add this extra piece to shield that fuel line.

Come on, unknown 2024 Maverick owner! We showed you ours, how about, ah, popping your hood so we can look inside!

Ah, cheese and crackers...that sounds a little creepy...sorry about that.

Just trying to add a bit of levity.

Andy

My very early '24 looks like the OP's, Glens and @icegradner's. Mine was built the first week of that MY's production IIRC.

 

[MYNOMAV]

MY24 here

 

[icegradner]

OK guys, I am back (yard work) the extra insulation/protection that Andy has is exactly where the leak was.

Very interesting indeed. It will be even more interesting to see if they replace what was there with the older design from 22-24, or a the newer part from 25+. Thanks for keeping us up to date!

If this starts to be an issue for more people down the line, I wonder if we will see a recall for this? I'm sure, as other noted, Ford didn't add the extra protection for nothing!

 

[Waterick]

Seems to me from the description of the leaking area and the pictures, that the leak coincides with that area of the thin shielding in the OP's that has a nick in it. Could it also be the cause of the leak?

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