Ford Flex: P0442 EVAP System Leak
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Date: 2020-08-05
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Comments and reviews: 10
autos
So most fuel system leaks on Ford seem to be associated with severe corrosion on fuel inlet tubes. However you may also want to look for issues with degradation of o-ring seal on fuel pump/sender to tank assembly. It seems the plastic material used in sender assembly is reactive in some way to either fuel or temperature or time. Noted in plastic o-ring seal area are numerous fissures and fractures about 360 degree circumference. These fractures do not seem to be caused by stress or other common cause; they seem to be attributed to material-science issue in design or manufacturing. Fuel leaks from these fissures pools on top of tank when tank is filled or fuel splashes against seal while driving. Fuel vapors are periodically noted in cabin with EVAP error codes intermittently reported. Replace entire sender assembly or coat fractures with quality sealant for cost effective fix.
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So most fuel system leaks on Ford seem to be associated with severe corrosion on fuel inlet tubes. However you may also want to look for issues with degradation of o-ring seal on fuel pump/sender to tank assembly. It seems the plastic material used in sender assembly is reactive in some way to either fuel or temperature or time. Noted in plastic o-ring seal area are numerous fissures and fractures about 360 degree circumference. These fractures do not seem to be caused by stress or other common cause; they seem to be attributed to material-science issue in design or manufacturing. Fuel leaks from these fissures pools on top of tank when tank is filled or fuel splashes against seal while driving. Fuel vapors are periodically noted in cabin with EVAP error codes intermittently reported. Replace entire sender assembly or coat fractures with quality sealant for cost effective fix.
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My
I like your attitude.
You remind me of, well, me.
I loved working in the garage at my dad's place.
That was years ago, miss it dearly.
At least I have a carport to work on now, however. I would love to have that car lift, though.
Keep up the videos.
I try to record as often as I can when it comes to working on my truck and car.
Enjoyable, at times.
Working on a P0442, and a P0305, and a P0456
Oh, what fun. (No smoke machine here, though)
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I like your attitude.
You remind me of, well, me.
I loved working in the garage at my dad's place.
That was years ago, miss it dearly.
At least I have a carport to work on now, however. I would love to have that car lift, though.
Keep up the videos.
I try to record as often as I can when it comes to working on my truck and car.
Enjoyable, at times.
Working on a P0442, and a P0305, and a P0456
Oh, what fun. (No smoke machine here, though)
reply
Sirius
Back in the day when the gas cap was behind the license plate? When it was annoying to hold the license plate down while fueling the vehicle and even more annoying when trying to replace the gas cap? Or how about the Chargers, and others, that put the fuel fill on the back of the car so that when you were done fueling the gas would drip on the paint?
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Back in the day when the gas cap was behind the license plate? When it was annoying to hold the license plate down while fueling the vehicle and even more annoying when trying to replace the gas cap? Or how about the Chargers, and others, that put the fuel fill on the back of the car so that when you were done fueling the gas would drip on the paint?
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Joshua
I am really enjoying your videos Eric! I am a postal mechanic here in the midwest and we have massive rust problems here and evap codes for days, We have a about 500 08 Uplanders in our chunk of the fleet and our smoke machine gets plenty of use. In contrast the right hand drive Fords don't give us many problems but they do have gas caps!
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I am really enjoying your videos Eric! I am a postal mechanic here in the midwest and we have massive rust problems here and evap codes for days, We have a about 500 08 Uplanders in our chunk of the fleet and our smoke machine gets plenty of use. In contrast the right hand drive Fords don't give us many problems but they do have gas caps!
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Cobra
Excellent video, made me laugh. Right before you said it, I thought to myself, what a ridiculous design. The engineer who drew that up probably takes a train to work. Had a evap issue with my 07 caravan with no valve to smoke. Ended up being the nvld. Do you have any recommendations for a do it your self smoke machine? Thanks, Chuck
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Excellent video, made me laugh. Right before you said it, I thought to myself, what a ridiculous design. The engineer who drew that up probably takes a train to work. Had a evap issue with my 07 caravan with no valve to smoke. Ended up being the nvld. Do you have any recommendations for a do it your self smoke machine? Thanks, Chuck
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Bob
No smoke machine needed here, looked at the filler neck on a 2001 Taurus and she looked really mean. Changed the filler tube with the cheapest filler neck other than OEM cheaper than Dorman, she not too long for this world. Just wanted her to make it thru her last emission test. hahaha Ran a drive cycle within one day and she passed.
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No smoke machine needed here, looked at the filler neck on a 2001 Taurus and she looked really mean. Changed the filler tube with the cheapest filler neck other than OEM cheaper than Dorman, she not too long for this world. Just wanted her to make it thru her last emission test. hahaha Ran a drive cycle within one day and she passed.
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Zee
Just a hint. A good plug are these plastic thingis you use when you Play Golf to balance the Ball on when you hit the Ball first time. I dont Play Golf (i drive Golf. So i dont know the name. These thingis are conical and fit different tubes and places. I. Use Them f. eks to plug the fuelline on my old beetle when pulling the engine.
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Just a hint. A good plug are these plastic thingis you use when you Play Golf to balance the Ball on when you hit the Ball first time. I dont Play Golf (i drive Golf. So i dont know the name. These thingis are conical and fit different tubes and places. I. Use Them f. eks to plug the fuelline on my old beetle when pulling the engine.
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Jake
For future, On cap less fillers they have funnels to open the valve to add gas from cans and you can use silicone lightly spritz to spray that valve to lube that seal. You can find the funnel under back seat or in with spare tire. Hope all is well I am not a fan of this system at all.
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For future, On cap less fillers they have funnels to open the valve to add gas from cans and you can use silicone lightly spritz to spray that valve to lube that seal. You can find the funnel under back seat or in with spare tire. Hope all is well I am not a fan of this system at all.
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Chris
I own a flex and have the same problem. I just reset the code a few days before I have an emission inspection. I'm not putting money into my 34k piece of shit. My 6. 4 powerstroke had piston 8 crack in half too. Ford is total junk. I used to be a Ford man. The keep word, used too
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I own a flex and have the same problem. I just reset the code a few days before I have an emission inspection. I'm not putting money into my 34k piece of shit. My 6. 4 powerstroke had piston 8 crack in half too. Ford is total junk. I used to be a Ford man. The keep word, used too
reply
Neil
I can't begin to tell you how much I appreciate your videos. I'm not a mechanic but love to do mechanical things. You are the most knowledgeable auto mechanic. You are incredible! Thank you. Really Thank you.
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I can't begin to tell you how much I appreciate your videos. I'm not a mechanic but love to do mechanical things. You are the most knowledgeable auto mechanic. You are incredible! Thank you. Really Thank you.
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