Ford Flex Smells Like Gas

Common Causes of Fuel Odors in Your Ford Flex and Essential Safety Precautions to Take

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Reviewed by
Devin Cabugcal
Written by RepairPal Car Genius
Updated January 14, 2025
0%
15% chance it's the
Gas Cap
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40% chance it's the
Emissions Control System
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45% chance it's
Something else
The most common reasons a Ford Flex smells like gas are the gas cap, the fuel system, or the emissions control system.
  • Gas Cap: A loose or damaged gas cap can cause fuel vapors to escape, triggering the check engine light and potentially affecting fuel system pressure.
  • Emissions Control System: A faulty emissions control system can lead to increased hydrocarbon emissions and trigger the check engine light due to malfunctioning components like the EGR valve or O2 sensors.
Proper diagnosis will determine the exact cause of your symptom, saving you money on unnecessary repairs. The diagnostic experts at RepairPal Certified shops have the right tools and experience to solve any symptom.

How much does it cost to fix a Ford Flex smells like gas?

Common Repairs

The total repair cost will vary based on the condition of your vehicle and the number of repairs needed to fix your symptom. Proper diagnosis will save you money by finding the exact repairs needed to fix your car right the first time.

A failing catalytic converter can cause a vehicle to fail emissions tests and turn on the check engine light. The exhaust might have an unusual smell. A restricted catalytic converter can result in a loss of engine power.

» LEARN MORE: How to tell if your catalytic converter is failing

The check engine light will illuminate any time there is a failed EVAP system test. This will be indicated by the various on-board diagnostics trouble codes that are stored in the vehicle's memory. Also, in some models, there may be a popping sound accompanying the check engine light, as the leak detection pump continuously attempts to pressurize the fuel tank. The canister may also cause difficulty starting the engine, a rough idle, and poor fuel mileage.

The check engine light will illuminate any time there is a failed EVAP system test. This will be indicated by the various on-board diagnostics trouble codes that are stored in the vehicle's memory. Also, in some models, there may be a popping sound accompanying the check engine light, as the leak detection pump continuously attempts to pressurize the fuel tank. A fuel tank leak may also cause difficulty starting the engine, a rough idle, and poor fuel mileage. When a fuel tank is simply corroded to the point of failure, the exterior tank condition rarely shows damage. The inside of the fuel tank will be rusted or corroded, and rust flakes or other debris may be floating in the fuel.

For most vehicles, the only symptom will be a check engine light or fuel tank filler cap light illuminating on the driver instrument cluster. This is to signal that there is an evaporative emissions (EVAP) leak. In some situations, the vehicle may take longer than normal to start, or, more rarely, the engine may not start at all. on-board diagnostic (OBD) trouble codes will refer to EVAP system failures such as a small or massive EVAP system leak. Lastly, the powertrain control module may notice a lean running condition, which could even lead to random and infrequent misfires.

Troubleshooting Gas Smell Issues in a Ford Flex

When faced with a gas smell in your Ford Flex, it's essential to approach the issue methodically. Begin by inspecting the gas cap, as a loose or damaged cap is often the simplest and most common culprit. Ensure it is securely tightened and check for any signs of wear or cracks. If the gas cap appears fine, turn your attention to the fuel system; look for leaks around fuel injectors and hoses, as these can emit strong odors if compromised. Next, examine the emissions control system, particularly the EVAP system, for any visible damage or leaks, such as a cracked canister, which can allow gas vapors to escape. Additionally, inspect the PCV hose, as a faulty hose can contribute to gas smells; replacing it may resolve the issue. If these steps do not eliminate the odor, consider the possibility of a PTU failure in all-wheel-drive models, which can also produce a gas-like smell inside the cabin. Finally, consult your dealer for any relevant Technical Service Bulletins (TSBs) that may provide further insights into specific issues affecting your vehicle. By following this diagnostic approach, you can systematically identify and address the source of the gas smell in your Ford Flex.

What Could Cause a Gas Smell in a Ford Flex?

When you detect a gas smell in your Ford Flex, it’s crucial to identify the underlying cause to ensure both safety and vehicle performance. One of the most common culprits is a fuel leak, which can occur anywhere in the fuel system, from the tank to the injectors. A faulty gas cap is another frequent issue; if it fails to seal properly, it can allow fuel vapors to escape, creating a noticeable odor. Additionally, a leak in the evaporative emissions system can lead to gas smells, often linked to a cracked canister that allows vapors to escape. Overfilling the gas tank is a simple mistake that can also result in a gas smell, as excess fuel may spill into the evaporation system. If you notice the smell intensifying after running the engine, it could indicate a leaking fuel injector, which poses a significant fire hazard. To address these issues, start by inspecting the gas cap and fuel lines for visible leaks, and consider using a fuel system cleaner to help maintain the integrity of the system. If the problem persists, it’s advisable to consult a qualified mechanic for a thorough inspection and repair.

What Should You Do If Your Ford Flex Smells Like Gas?

If your Ford Flex emits a gas smell, it is crucial to act swiftly, as this could indicate serious issues that may compromise your safety and lead to costly repairs. Start by thoroughly inspecting your vehicle for any signs of fuel leaks, particularly in the engine bay and undercarriage, as gasoline can evaporate quickly, making leaks hard to detect. If you find any leaks, refrain from using the vehicle until the problem is resolved. Additionally, consult Ford's service bulletin for specific guidance on common issues, such as a faulty PCV hose or problems with the EVAP system, which can also contribute to gas odors. If the smell intensifies after running the engine, it may signal a leaking fuel injector, which poses a significant fire hazard; in this case, do not operate the vehicle until the injector is replaced. To mitigate gas odors from a capless fuel system, consider investing in a locking fuel filler cap designed for your Ford Flex. By addressing these concerns promptly, you not only protect yourself and others on the road but also prevent further damage to your vehicle.

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