help help help im about to lose it!! 2004 eddie bauer stalls!!!

I think we have done just about everything to try to fix the stalling problem. We even reprogrammed key just to make sure. But she f.... did it again today!!!! She's been running great for couple of months and out of the blue. BOOM!!! With this exception that couple of days ago I started to getting "Check charging system" message. We replaced battery a month ago. We checked voltage and it seems that alternator runs perfect. It starts perfectly . No noise nothing. My husband is a mechanic (aircraft) but very well informed with cars so we r not total ignorants here (my dad is a master mechanic as well) . I have read horror stories about 5.4 tritons and im starting to give up on her. So much money and nobody knows from ford licensed mechanics to my dad and husband themselves.
So here is what happens.
I'm starting car with no problem. Drive it to son's school appx. 7 miles one way. On the way back on the highway going 70mph i feel like it slows down on me for a sec and then jerks forward and drives normally (kinda like she got a hiccup. Not enough air) ,then she does it again. Still goes. I'm taking an exit and BOOM shuts off. No brakes no steering power. No panic. I switch it to neutral stop it eventually switch it to park. Starts back up with no problem. I'm driving from another 2 miles BOOM again!!! Again stars with no problem. I got home opened a hood . may be she i sucking some air. I,m listening cant hear damn shit. Engine runs fine. On idle now, and 3,2,1 dies. Starts back again, no problem.... No codes nothing!!! Nobody knows whats going on. We r playing eenie meenie miney mo. What I've noticed is that it usually happens when i have 1/4 of tank. Fuel pump was replaced in 2014. I'm so furious now I'm about to replace cam and crankshaft sensor, TCM too, or I will just f... dump her of the bridge!!!!!

2004 Expedition 5.4 Eddie Bauer.

Are you 100 percent sure your SUV is 2004, and not an early 2005. If it is 2005, you or your hubby might want to crawl under rear of SUV and see if you have a fuel pump control module. It would be mounted on a frame rail near spare tire. On expeditions they were only used on 2005/06 years. They are famous for corroding and causing all kinds of havoc. If your production date is late in 2004, you may have a 2005 model. Keep us posted as to your results. P.S you mentioned this problem occurs at about 1/4 tank. Has anyone done a fuel pressure test? When the shop replaced pump last time, did the stalling go away?


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After conferring with another forum member he thought that your problem may be with the fuel pump relay. The relay through your year and a lot of second generation expeditions are soldered in. Apparently the connections break loose, and cause a break of current to the fuel pump circuit. It's very common on these models. If your hubby is handy, it can be repaired. Or you can get another fuse/ relay panel. Their are companies out there that can repair yours. You might want to check out the relay problem, before you start throwing other parts at your SUV.


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Try wiggling every wiring harness you could find -see if you could replicate the problem.

Normally I'd say yes if it was another circuit, and was intermittent, but this is a fuel delivery problem that can't be wiggled to make contact when driving/ idling. You have to remove relay / resolder to fix this problem. At least this is a possibility.


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My vote is the fuel pump relay.

Well that's the starting point for now. Sure hope her hubby put in the fuel pump himself. Big bucks if not! And still has condition. Wouldn't be the first time though!


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I hate throwing parts at things but in this case I think it would serve them well to open up that relay box and see if that relay is showing signs of burning

On expeditions the problem is not just the relay but the fact that their soldered to to the fuse box. They need to be re soldered. Their not just a pop out relay like on other Fords. Another brilliant Ford design. Makes me wonder what these boneheads are thinking. Like putting 4 instead of 8 spark plug threads on an aluminum cylinder head, on my 2000 expedition. And amazingly these guys and girls keep their jobs at Ford. God bless the unions!


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Thank you guys so much for advice. The problem is.... We are living now in UAE and these people here (mechanics) have no idea about anything. My husband can do anything to that car but the problem is that he doesn't have so many tools to do the job. It's a nightmare here. We got that car from a guy 2 years ago. It was bought in California and brought straight here. I still have a window sticker (they payed 42k for it). They sold her with all documents and bills from mechanics. That's why i know the pump was replaced but to be honest my husband doubt they did it. He doesn't believe any of these idiots here. We will check relay like you suggested and we will be going from there. My hubby and father both think it must be something cutting fuel off. So may be relay indeed. I had the same exact thing happened to my Odyssey. After putting nearly 700$ and playing hide and seek we finally found out that main relay was overheating and sending codes to PCM and shutting down the engine. So I'm hoping for the relay. He's been driving her for a past week and nothing. She is purring like a kitten. They (previous owners)put close to 15K in repair according to the bills!!!!!! We were like WTF??!!!! And my hubby thinks that this exact problem started long time ago but first owners had no clue about anything so they were taking her to Ford hoping she'll be fixed but idiots here didn't know either what's going on (no codes) so they were replacing shit part by part. We think they just got too tired of spending money and they sold her (don't blame them). We payed 4k cash for her and I was aware it's an old car and probably needing some tlc but shit..... First time we changed oil just right after we bought her we did engine flush and what we saw came out of that poor car was horrifying!!!! So at this point I don't know if I should put any more time and money into that car, or just take it to junk yard. But ffffuuuukkkkk I really like her she is so comfy....