Fuel Tank Selector Valve and Other Problems

Thanks for getting back to me. Here's what I found out: The Fuel Tank Selector Valve poses many frustrating problems. It's really a problem waiting to happen. It was a terrible mistake for Ford to make dual tank vehicles. In my case, the new OEM selector valve that the Ford dealership put in my van turned out to be faulty. These valves have O-rings and some of these "new" OEM valves in vendor's inventory were probably manufactured 25 years ago. So, these O-Rings have probably oxidized and dried out. My van runs like crap on the front tank and runs much better on the rear tank. Also, the selector valve really constricts the gas flow. So, to use an analogy, if an artery to your heart is constricted, then you just might need bypass surgery. Therefore, the best solution to my problem is to bypass the selector valve. And many people have done just that. So, I told the dealer to take two metal fuel connector tubes and connect them to the main and return fuel lines from my rear tank and connect the other ends leading to the main fuel pump bypassing the selector valve. I'll just have one working fuel tank - my rear tank. But the good news is I won't have to deal with this stupid selector valve anymore!

Please share this information with the community - It could save someone's life!

Beginning around the 1980s Ford made vehicles with dual fuel tanks that came with mechanical Fuel Tank Selector Valves (“FTSV”) and it soon became apparent that the mechanical FTSV was inherently flawed. Unfortunately, “[o]n March 20, 1993, a 1985 Ford F-150 XLT caught fire the result of which proved horrific: four children were burned to death.” [Emphasis added.] Smith v. Ford Motor Co, 908 F. Supp. 590, 591 (1995) (Dist. Ct, ND Indiana). Evidence showed the fire very likely started in the mechanical FTSV, which routes gasoline from either the front fuel tank or the rear fuel tank. On information and belief, Ford had two recalls for their mechanical FTSV, the first recall around 1992. However, beginning around 1991, Ford decided to phase out the mechanical FTSV and began to use the much more dependable electric FTSV, which seldom fails. Ford also stopped directly manufacturing the mechanical FTSV part.
But what would happen to all of the vehicles still operating with mechanical FTSVs? Unfortunately, many owners of dual fuel tank vehicles with mechanical FTSVs still experienced serious problems. In cases where the mechanical FTSV malfunctioned, there were instances of fuel backing up into the other fuel tank and overflowing and spilling gasoline out through the gas cap and onto the ground. That was obviously a fire hazard as well as a chemical hazard. There were instances of vehicles experiencing complete engine failure which stranded motorists. As the years went by, more and more of these mechanical FTSVs began to fail. Also, it became much more difficult to find a Ford OEM (original equipment manufacturer) mechanical FTSV. When a Ford OEM mechanical FTSV was found, it was sometimes so old that the seals and/or the rubber O-ring in the valve had already dried out and deteriorated. So replacing the original faulty mechanical FTSV with ostensibly a “new” mechanical FTSV often resulted in a repeat failure. So many owners got fed up with this mechanical FTSV problem that they began to bypass the mechanical FTSV with fuel line connectors. But Ford and its dealers refuse to perform this bypass procedure. One viable and safe solution for Ford and its dealers would be to replace the faulty mechanical FTSV with a new electric FTSV. Another option would be to connect new complete fuel lines (a main fuel line and a return fuel line) from one of the fuel tanks to the main fuel pump, effectively converting the vehicle to a one fuel tank system. But the solution Ford and its dealers insist on is to replace a faulty mechanical FTSV with another “new” mechanical FTSV that might have been manufactured so long ago that its seals and/or O-ring may have deteriorated. Replacing one bad part with another bad part is the epitome of irresponsibility and stupidity! It is also extremely reckless! Four children died because of a dangerous mechanical FTSV and Ford has failed to remediate this problem. Shockingly, Ford’s solution is to replace a faulty mechanical FTSV with a potentially dangerous “new” mechanical FTSV.
So why is Ford and its nationwide dealerships refusing to address the mechanical FTSV problem? There may be a number of reasons. To begin with, it’s not good P.R. To discuss this dangerous mechanical FTSV problem since four children were burned to death. The “new” OEM mechanical FTSVs sell for around $500 and the labor cost to install it runs around $500 or more, so the dealer can charge around $1,000 or more for replacing the mechanical FTSV. However, a simple bypass around the mechanical FTSV costs approximately $250, including parts and labor. So here we have it - the dealer has no financial incentive to permanently fix the mechanical FTSV problem.