Delamination of the diesel fuel tank can occur resulting in a loss of power due to debris clogging the fuel filters. In some cases the fuel injection pump and/or fuel injectors have also been damaged. Ford has issued a service bulletin (#Google+
Car Problem Reports
Ford E-350 Delamination of Diesel Fuel Tank
Ford E-350 Problem
Exhaust & Emissions Affected: 6.0L V8 Diesel Turbo
Average Mileage: 130,489 mi (61,568 mi - 254,000 mi)
GRAY LOOKING FLAKES IN THE FUEL TANK // FUEL SENDING UNIT AND FRAME MOUNTED FUEL PUMP IS CLOGGED FROM THAT STUFF... THE TANK PROTECTIVE COATING IS COMING LOOSE AND CAUSES THIS PROBLEM....SYMTOMS ARE LOST OF POWER / WHITE SMOKE / ROUGH IDLE.. I THINK FORD SHOULD RECALL THIS BECAUSE OF THE POORLY DESIGNED FUEL TANK WE HAVE THE COSTLY REPAIR BILLS AND THE HEADACHE THAT COMES WITH IT....
Visitor, 2005 Ford E-350, 82,000 mi
Delamination of gas tank caused clogged fuel system, dealer wants $5800+ to repair. We bought at Fred Beans in Boyertown, PA and they have done all service but told us we should be cheking fuel filter, we would have seen flakes in the fuel filter. They changed all filters but never told us of any problems and they are more qualified than we are.
Visitor, 2004 Ford E-350, 138,000 mi
The fuel tank on one of our diesel E-350 vans was diagnosed as being faulty and in need of replacement. The dealer has quoted $1,700.00 to do so and with no factory assistance from Ford, there is little one can do other than keep changing fuel filters and their not cheap. The factory should at least provide some assistance in this, it is clearly a common problem.
Visitor, 1999 Ford E-350
Delamination of Disel Fuel Tank and failure of Fuel Sending Unit and a whole bunch of related bills due to guesswork of mechanics that need to get paid.
Visitor, 2001 Ford E-350, 136,000 mi
Sudden loss of power. Replaced fuel filter. Still no power. Garage is boiling the fuel tank. Hoping this works. Ford is standing by its name, Fix Or Repair Daily!
Visitor, 2004 Ford E-350, 61,568 mi
Fuel gauge goes from empty to full just driving around the block. I believe sending unit is bad. The tank is delaminated.
Is this where you vent . 1st time 2008 complete change new tank and everthing after good price around 3400. 2nd time 2012 complete change again 4300 dollars this time cleaned tank and recoated ,2500 miles later changed filter and full of debris . Why hasn't a company made a replacement fuel tank out of aluminium or plastic yet. Anybody found solutions
Visitor, 2001 Ford E-350, 254,000 mi
Dealer had to remove tank, replace the $650.00 sending unit and have the tank cleaned out. I wanted the tank replaced but Ford does not have a replacement tank available as of now. The story I got was that they were redesigning the tank and hadn't yet approved the new model. They currently have almost 100 of these tanks on back-order with no release date anticipated in the near future. The only option I was left with was reuse the old tank any possibly have the same problem again later on down the road.
Visitor, 2006 Ford E-350, 80,000 mi
no power rust in fuel filter